Starter Motor: Testing and Inspection
SERVICE ADJUSTMENT PROCEDURES FOR PINION GAP ADJUSTMENTFig. 4 Pinion Gap Adjustment (Part 1 Of 3):
1. Disconnect the field coil wire from the M-terminal of the solenoid.
2. Connect a 12 V battery the S-terminal and the M-terminal.
3. The pinion will move out.
CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
Fig. 4 Pinion Gap Adjustment (Part 2 Of 3):
4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge.
Pinion gap : 0.5-2.0 mm (0.02-0.079 in.)
5. If the pinion gap is out of specification, adjust by adding or removing gaskets between the solenoid and the front bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal of the magnetic switch.
2. Connect a 12 V battery between the S-terminal and the M-terminal.
CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
3. If the pinion moves out, then the pull-in coil is good. If it doesn't move out, replace the magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect the field coil wire from the M-terminal of the magnetic switch.
2. Connect a 12 V battery between the S-terminal and the body.
CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
3. If the pinion moves out, everything is in order. If the pinion moves back and forth repeatedly the hold-in circuit is open. Then replace the magnetic switch.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-Volt battery to starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat as shown is the illustration.
3. Connect a voltmeter (15-Volt scale) across starter motor.
4. Rotate carbon pile to the off position.
5. Connect battery cable from battery negative post to starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11 Volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely:
Current : Max. 90 Amps
Speed : Min. 3,000 rpm
MAGNETIC SWITCH RETURN TEST
1. Disconnect field coil wire from the M-terminal of the magnetic switch.
2. Connect a 12 V battery between M-terminal and the body.
NOTE: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
3. Pull pinion out and release. If pinion returns quickly to its original position, everything is in order. If it doesn't, replace the magnetic switch.
INSPECTION
BRUSH HOLDER
Check for continuity between the brush holder plate and the brush holder.
The normal condition is no continuity.
OVERRUNNING CLUTCH
1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction but should not rotate in opposite direction. If clutch does not function properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is damaged, also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING
Inspect bushing for wear or burrs. If bushing is worn or burred, replace front bracket assembly or rear bracket assembly.
SERVICE POINTS OF ASSEMBLY
INSTALLATION OF THE STOP RING AND SNAP RING
Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring
CLEANING STARTER MOTOR PARTS
1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
REPLACEMENT OF BRUSHES AND SPRINGS
1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail
3. Sand pigtail end with sandpaper to ensure good soldering.
4. Insert pigtail into hole provided in new brush and solder it. Make sure that pigtail and excess solder do not come out onto brush surface.
5. When replacing ground brush, slide the brush from brush holder by prying retaining spring back.