Starter Components Inspection

Armature 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 ammeter.

Standard diameter:
30.0 mm (1.181 in.)

Minimum diameter:
29.0 mm (1.142 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, repair or 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 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 (1.79 - 2.41 kg, 4.0 - 5.3 lb)

Minimum spring installed load:
11.8 N (1.20 kg, 2.7 lb)

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, idler gear and 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
Hold the starter clutch and rotate the pin ion gear counterclockwise. and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.

3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY
Service and Repair







Bearings
1. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.

If resistance is felt or the bearing sticks, replace the bearing.







2. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.

If resistance is felt or the bearing sticks, replace the bearing.