Starter Motor: Testing and Inspection

Repair or replace necessary parts if extreme wear or damage is found during inspection.

Armature




^ Measure the outer diameter of commutator, and replace with a new one if it is out of the limit.

Standard Limit mm (in)
33(1.30) 32(1.26)




^ Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected).




^ Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core,armature core and shaft. Replace commutator if there is continuity (i.e.. internally grounded).




^ Measure runout of armature core and commutator with a dial gage. Repair or replace, if it exceeds the limit.

Name Standard Limit mm (in)
Armature 0.05 (0.002) max. 0.1(0.004)
Commutator 0.05 (0.002) max. 0.1(0.004)




^ Polish the commutator surface with sand paper #500 to #600 if it is rough.




^ Measure the depth of insulator in commutator. Repair, if it is below the limit.

Standard Limit mm (in)
0.5-0.8 (0.02-0.03) 0.2(0.008)

Brush




^ Measure the length of brush.
Replace with a new one, if it is below the limit.

Standard Limit mm (in)
16(0.63) 11(0.43)

Brush holder




^ Check for continuity between brush holder (+) and base (-). Replace, if there is continuity (i.e., insulation is broken).

Magnetic switch




^ Continuity of shunt coil
Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).




^ Continuity of series coil
Check for continuity between terminals S and M. Replace, if there is no continuity (i.e., coil is disconnected).




^ Continuity of contacts
With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty).

Pinion




^ Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated reversely. If not, replace the pinion.

Yoke assembly




^ Check a magnet inside the yoke.
Replace the yoke assembly if it is broken.

Ball bearing




^ Clamp the inner race of ball bearing with your finger, and check for sticking or play when rotating the outer race.
Replace, if abnormality is found.




^ Measure inner diameter of bushing in the rear cover, and replace if it exceeds the limit.

Standard Limit mm (in)
12.5(0.49) + 0.027 (0.001) 0 0.1(0.004)




^ Measure inner diameter of bushing in the center bracket (P), and replace if it exceeds the limit.

Standard Limit mm (in)
18 (0.71) + 0.127 (0.005) + 0.1 (0.004) 0.1(0.004)