Disassembly and Reassembly

Starter Components:

DISASSEMBLY

REMOVAL OF SNAP RING AND STOP RING




1. Press the stop ring to the snap ring side using a socket wrench, to the snap ring side.




2. After removing the snap ring (using snap-ring pliers), remove the stop ring and the overrunning clutch.

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.

CHECKING THE COMMUTATOR




1. Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.

Standard value
Armature deflection : 0.05 mm (0.002 in.)

Limit
Armature deflection : 0.1 mm (0.0039 in.)




2. Check the outer diameter of the commutator.

Standard value
Outer diameter of the commutator: 29.4 mm (1.157 in.)

Limit
Outer diameter of the commutator: 28.4 mm (1.118 in.)




3. Check the depth of the undercut between segments.

Standard value
Depth of the undercut between segments : 0.5 mm (0.020 in.)

Limit
Depth of the undercut between segments: 0.2 mm (0.0079 in.)




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.

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.





REASSEMBLY OF THE STOP RING AND SNAP RING
Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring