Starter Components Inspection

ARMATURE COIL







1. INSPECT THAT COMMUTATOR IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature.







2. 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.

COMMUTATOR
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES
If the surface is dirty or burnt, clean 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 indicator, measure the circle runout.

Maximum circle runout:
0.05 mm (0.0020 in.)

If the circle runout is greater than the maximum, correct it on a lathe.







3. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.

Standard diameter:
1.4 kW type: 30.0 mm (1.181 in.)
1.8kW type: 35.0 mm (1.380 in.)

Minimum diameter:
1.4 kW type: 29.0 mm (1.142 in.)
1.8 kW type: 34.0 mm (1.340 in.)

If the diameter is less than the minimum, replace the armature.







4. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign material. Smooth out the edge.

Standard undercut depth:
1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW type: 0.7 mm (0.028 in.)

Minimum undercut depth:
0.2 mm (0.008 in.)

If the undercut depth is less than the 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. INSPECT THAT FIELD COIL IS NOT GROUNDED
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. 1.8 kW type:
INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between terminal (A) and (B).

Standard resistance:
At 20°C (88°F): 1.4 - 1.9 Ohm

If the resistance is not as specified, repair or replace the field frame.








BRUSHES
INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.

Standard length:
1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW type: 15.0 mm (0.591 in.)

Minimum length:
1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW type: 9.0 mm (0.354 in.)

If the length is less than the 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.

Spring installed load:
1.4 kW type:
17.6 - 23.5 N (1.79 - 2.41 kg, 3.9 - 5.3 lb)
1.8kW type:
21.5 - 27.5 N (2.19 - 2.81 kg, 4.9 - 6.2 lb)

Minimum spring installed load:
1.4 kW type: 11.8 N (1.2 kg, 2.6 lb)
1.8 kW type: 12.7 N (1.3 kg, 2.7 lb)

If the installed load is less than the minimum, replace the brush springs.







BRUSH HOLDER
INSPECT INSULATION OF BRUSH HOLDER
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, idler gear and clutch assembly for wear or damage.

If damaged, replace the gear or clutch assembly. If damaged, also check the flywheel ring gear for wear or damage.







2. INSPECT CLUTCH
Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion counterclockwise and check that it locks.

If necessary, replace the clutch assembly.



BEARINGS
1. INSPECT BEARINGS
Turn each bearing by hand while applying inward force.

If the resistance is felt or if the bearing sticks, replace the bearing.







2. IF NECESSARY, REPLACE BEARINGS
a. Using SST, remove the bearing.
SST 09286-46011







b. Using SST and a press, press in a new bearing.
SST 09201-41020