Component Inspection
STARTER INSPECTION AND REPAIRArmature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segment, replace the armature.
2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES
If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
3. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter:
30.0 mm (1.181 in.)
Minimum diameter:
29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.
4. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a hacksaw blade.
Field Frame (Field Coil)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame.
2. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, replace the field frame.
Brushes
INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length:
15.5 mm (0.610 in.)
Minimum length:
10.0 mm (0.394 in.)
If the length is less than minimum. replace the brush holder and field frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring separates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.8 - 2.4 kgf, 3.9 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is less than minimum. replace the brush springs.
Brush Holder
INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
Clutch and Gears
1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged. also check the drive plate ring gear for wear or damage.
2. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.
Bearings
1. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is fell or the bearing sticks. replace the bearing.
2. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-46011
(b) Using a press, press in a new rear bearing.
3. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
4. IF NECESSARY, REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-46011
(b) Using SST and a press, press in a new bearing.
NOTE: Be careful of the bearing installation direction.
SST 09820-00030
Magnetic Switch
1. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
2. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
MAGNETIC SWITCH TERMINAL KIT PARTS REPLACEMENT
1. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
2. INSPECT CONTACT PLATE FOR WEAR
Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear:
0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
3. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810-38140
(b) Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
(c) Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt. contact plate, terminal insulator (inside) and insulation paper.
4. REINSTALL TERMINAL KIT PARTS
(a) Install these new parts:
Terminal 30:
(1) Insulation paper
(2) Terminal insulator (inside)
NOTE: Be careful to install the terminal insulator in the correct direction.
(3) Contact plate
(4) Terminal bolt
(5) O-ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
(7) Wave washer
(8) Terminal nut
Terminal C:
(1) Terminal insulator (inside)
NOTE: Be careful to install the terminal insulator in the correct direction.
(2) Contact plate
(3) Terminal bolt
(4) O-ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
(b) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTE:
^ Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
^ If the contact plate is not pressed down with the specified pressure. the contact plate may tilt due to coil deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (170 kgf.cm, 12 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.
Torque: 2.5 N.m (26 kgf.cm, 22 in.lbf)