Overhaul

Starting System - Starter Overhaul:

Starter Overhaul

Brush Holder Removal
1. Remove the starter.
2. Disconnect the wire from the M terminal, and remove the end cover.




3. Place a 29.4 mm (1.16 in.) outside diameter plastic pipe on the armature.




4. Move the brush holder (A) up to the pipe (B) while holding the pipe so the brushes do not pop out from the holder.

Armature Inspection and Test
5. Disassemble the starter as shown at the beginning of this procedure.




6. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.




7. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B)




8. Check the commutator diameter. If the diameter is out of the service limit, replace the armature.




9. Measure the commutator (A) runout.
- If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
- If the commutator runout is not within the service limit, replace the armature.




10. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).




11. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.




12. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attached to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.




13. Check with an ohmmeter for continuity between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If there is continuity, replace the armature.

Starter Brush Inspection




14. Measure the brush length (A). If it is shorter than the service limit, replace the brush holder assembly.

Starter Brush Holder Test




15. Check for continuity between the (+) brush (A) and (-) brush (B). If there is continuity, replace the brush holder assembly.

Planetary Gear Inspection




16. Check the planetary gears (A) and ring gear (B) Replace them if they are worn or damaged.

Overrunning Clutch Inspection
17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.




18. Rotate the overrunning clutch (A) in both directions. It should lock and move upward in one direction and rotate smoothly in the other direction. If it does not lock in either direction or if it locks both directions, then replace it.
19. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the idler gear and drive plate ring gear to see if the starter drive gear teeth are damaged.

Starter Reassembly
20. Install the armature into the housing.




21. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.




22. Install the end cover to retain the brush holder.