Component Inspection
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 diameter.
Standard diameter:
1.4 kW type: 30.0 mm (1.181 in.)
2.0 kW type: 35.0 mm (1.378 in.)
Minimum diameter:
1.4kW type: 29.0 mm (1.142 in.)
2.0 kW type: 34.0 mm (1.339 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:
1.4 kW type: 0.6 mm (0.024 in.)
2.0 kW type: 0.7 mm (0.028 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. 1.4 kW Type:
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.
3. 2.0 kW Type:
INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B).
Resistance:
1.5-1.9 Ohms at 20° C(68° F)
If the resistance is not as specified, replace the field frame
Brushes
INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length:
1.4 kW type: 15.5 mm (0.610 in.)
2.0 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.4 kW type: 10.0 mm (0.394 in.)
2.0 kW type: 9.0 mm (0.354 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:
1.4 kW type:
17.6 -23.5 N (1.8 -2.4 kgf, 4.0-5.3 lbf)
2.0 kW type:
21.5 - 27.5 N (2.2-2.8 kgf, 4.9-6.2 lbf)
Minimum spring installed load:
1.4kW type:
11.8 N (1.20 kgf, 2.6 lbf)
2.0 kW type:
12.7 N (1.30 kgf, 2.9 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 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 pinion gear clock wise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
If necessary, replace the clutch assembly.
Bearings
1. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
2. IF NECESSARY, REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-4611
b. Using a press, press in a new bearing.
3. INSPECT FRONT BEARING
Turn the 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 O9286-46011
b. Using 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.