Hitachi Starter # S 114-232 and # S 13-91
Disassembly of Starter MotorM1 Bushing cap
Remove cap from cover with a screwdriver.
M2 Bushing cover and solenoid
Remove lock washers, shims and four bolts. Remove cover. Remove solenoid.
M3 Carbon brushes
Remove brushes from holder. If necessary, use a steel wire (2 mm = 0.08 in). Remove brush holder.
M4 Starter body
Remove body from armature and drive end bearing housing.
M5 Armature
Remove:
- rubber and steel washers
- armature and shift arm.
M6 Stop ring
- tap down stop ring with a suitable socket
- remove lock washer, stop ring and drive.
Cleaning and Inspection
M7 Armature
The armature should not grind against pole shoes and field coils. Diameter of end of coil must not be more than that of armature coil. Max. radial throw = 0.05 mm (0.002 in). Test armature for arcing and open circuits with appropriate test equipment.
M8 Arcing
Test commutator for arcing to ground.
M9 Commutator
Brush path should be smooth and free from dint and oil.
Machine commutator if burnt or out-of-round:
Min. diameter = 39 mm (0.154 in).
Max. radial throw = 0.05 mm (0.002 in).
M10 Undercutting
The insulation should be ground to 0.6 mm (0.024 in) below surface of commutator if depth is less than 0.2 mm (0.008 in). Use a special commutator grinder or a hacksaw blade. If necessary, clean commutator with a fine.grade emery cloth.
M11 Drive
Inspect drive. Make sure that it runs correctly on thread. Check teeth. If damaged replace drive. (Also check starter motor ring gear.) Check that free wheel locks in direction of rotation and disconnects in opposite direction.
M12 Bushings
Clearance between armature shaft and bushings must not exceed 0.12 mm (0.005 in). Replace worn or damaged parts. Always replace the lock ring as it will have lost its spring force on removal.
M13 Replacement of self-lubricating bushings
Self-lubricating bushings do not wear significantly if they are treated correctly before installation.
Treating new bushings:
- place thumb over end of bushing
- fill bushing with engine oil
- using index finger, press to force oil out through pores.
- Place bearing housing on a suitable support and tap out worn bushing.
- Clean bushing hole, filing any rough surfaces.
- Press in new bushing with a suitable drift.
M14 Control solenoid
Test solenoid with an ohmmeter or buzzer. Make sure that current flows between terminal 50 and ground. Then test between terminal 50 and field coil terminal "M". If current does not flow there is an open circuit in the solenoid. The solenoid must therefore be replaced.
M15 Starter body
Field coils must not be burnt or melted, and they must not lie above pole shoes. Test coils for open circuits and arcing. Use an ohmmeter or buzzer. A test lamp connected to battery can also be used.
M16 Replacement of field coils
Identify pole shoes and field coils with respect to starter body so that they can be reinstalled correctly. It may be necessary to use an impact driver to release pole shoes. Make sure that new coils do not short to starter body.
M17 Brush holders
Make sure that carbon brushes sit correctly. Test positive brushes and make sure that they do not short or arc to ground. Replace worn or corroded springs. If necessary use a spring balance to test spring force.
M18 Replacement of carbon brushes
Replace brushes if they are less than 11 mm (0.443 in) in length (new brushes are 16 mm 0.6 in).
- use soldering iron to release old brushes
- solder on new brushes.
Solder quickly and with sufficient heat. On no account must solder run onto wire because this would prevent brush sliding in holder and weaken brush spring force.
Assembly of Starter Motor
M19 Lubrication
Lubricate components according to instructions below. Use Bosch lubricant or bearing grease P/N 1 161 133-2 and engine oil.
1. Smear a thin layer of bearing grease on ends of shaft, shims and lock washer.
2. Oil bushing.
3. Apply plenty of grease to armature and groove for shift arm.
4. Apply a thin layer of bearing grease to armature shaft.
5. Oil bushings.
6. Apply a thin layer of bearing grease to shift arm track and solenoid core.
M20 Drive
Install drive, stop ring and lock washer on armature shaft. Slide stop ring over lock washer.
M21 Shift arm and armature
Attach shift arm to drive. Install armature in drive end housing
M22 Control solenoid
Install solenoid, rubber and steel washers.
M23 Starter body and brush holder
Install body and holder. Connect wire to solenoid.
M24 Rear bearing housing
Install rods and tighten brush holder.
M25 Axial clearance
Install shims and lock washer. Check axial clearance.
Clearance = 0.03 - 0.1 mm (0.0012 - 0.039 in). Adjust using shims. Reinstall bushing cap. Test starter motor before installing in vehicle.
M26 Measurement of end float
Connect a battery to starter motor as shown.
Note: max. connected time = 30 sec. Solenoid will overheat if connected longer.
M27 Measure end float
- use finger to depress drive until clearance is taken up
- measure end float between drive and stop ring.
End float = 0.3 - 1.5 mm (0.012 - 0.06 in).
M28 Shims
- two different sizes are available, 0.5 mm and 0.8 mm. If thickness of shims at solenoid is increased, end float will become smaller by approx. twice shim thickness. Shims are supplied with kit P/N 1 276463-5.
M29 Starter motor terminals
B+30 = from battery
50 = from ignition switch terminal 50
16 = to ballast resistor, ignition coil
M = to starter motor field coils
M 30 Testing
Test starter motor on a test bench. If one is not available, use jump leads.
Hitachi S 114-232
1 Drive end bearing housing
2 Rubber and metal washers
3 Shift arm
4 Spring
5 Shims
6 Solenoid
7 Bushing
8 Drive
9 Centre bearing
10 Armature
11 Commutator
12 Lock ring
13 Stop ring
14 Field coil
15 Pole shoe
16 Starter body
17 Screw
18 Brush
19 Brush holder
20 Spring
21 Bushing
22 Bushing cover
23 Shims
24 Lock ring
25 Bushing cap
26 Rod