Starter Overhaul

NOTE: Do not wipe off the special grease applied to the area of the starter marked with an asterisk (*) when you disassemble or assemble it.

1. Starter - Exploded View

Exploded View

M/T

A/T


NOTE: Refer to the Exploded View if needed during this procedure.

M/T

1. End Cover - Remove
Remove the end cover.


2. Brush Holder Assembly - Remove
Remove the brush holder assembly.


3. Brush Holder - Test
Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.


4. Brush - Inspect

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

Brush Length
Standard (New):
15.8?16.2 mm (0.622?0.638 in)
Service Limit:
11.0 mm (0.433 in)


5. Armature Housing - Remove
Remove the armature housing.


6. Armature - Remove
Remove the armature.


7. Armature - Inspect
1.
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
2.
Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with ?500 or ?600 sandpaper (B).
3.
Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.
Commutator Diameter
Standard (New):
28.0?28.1 mm (1.102?1.106 in)
Service Limit:
27.5 mm (1.083 in)
4.
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.
Commutator Runout
Standard (New):
0.02 mm (0.0008 in) max.
Service Limit:
0.05 mm (0.0020 in)
5.
Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.
Commutator Mica Depth
Standard (New):
0.4?0.5 mm (0.016?0.020 in)
Service Limit:
0.15 mm (0.0059 in)
6.
Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
7.
Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.
8.
Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

8. Gear Housing - Remove
Remove the gear housing with the starter solenoid.


9. Overrunning Clutch - Remove
Remove the overrunning clutch.


10. Overrunning Clutch - Inspect
1.
Rotate the overrunning clutch (A) both ways. If it does not lock in either direction, or it locks in both directions, replace it.
2.
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 flywheel ring gear to see if the teeth are damaged.

A/T

1. End Cover - Remove
Remove the end cover.


2. Armature Housing - Remove
Remove the armature housing.


3. Armature - Remove
Remove the armature.


4. Armature - Inspect
1.
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
2.
Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 3, or recondition with ?500 or ?600 sandpaper (B).
3.
Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.
Commutator Diameter
Standard (New):
28.0?28.1 mm (1.102?1.106 in)
Service Limit:
27.5 mm (1.083 in)
4.
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.
Commutator Runout
Standard (New):
0.02 mm (0.0008 in) max.
Service Limit:
0.05 mm (0.0020 in)
5.
Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.
Commutator Mica Depth
Standard (New):
0.4?0.5 mm (0.016?0.020 in)
Service Limit:
0.15 mm (0.0059 in)
6.
Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
7.
Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.
8.
Use an ohmmeter to check for continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

5. Brush Holder Assembly - Remove
1.
Remove the push nut (A), contact spring (B), moving contact (C), and brush springs (D).
2.
Remove the brush holder assembly.

6. Brush Holder - Test
Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.


7. Brush - Inspect

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

Brush Length
Standard (New):
11.1?11.5 mm (0.437?0.453 in)
Service Limit:
4.3 mm (0.169 in)


8. Planetary Gear - Inspect
Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged.


9. Internal Gear - Remove
Remove the internal gear.


10. Switch Plunger and Gear Plunger - Remove
Remove the switch plunger (A) and the gear plunger (B).


11. Overrunning Clutch - Inspect
1.
Holding the drive gear (A), turn the gear shaft (B) counterclockwise. Check that the drive gear comes out to the other end. If the drive gear does not move smoothly, replace the gear cover set.
2.
Holding the drive gear, turn the gear shaft clockwise. The gear shaft should turn freely. If the gear shaft does not turn freely, replace the gear cover set.
3.
If the drive gear is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately.


NOTE: Refer to the Exploded View if needed during this procedure.

M/T

1. Overrunning Clutch - Install
Install the overrunning clutch.


2. Gear Housing - Install
Install the gear housing with the starter solenoid.


3. Armature - Install
Install the armature.


4. Armature Housing - Install
Install the armature housing.


5. Brush Holder Assembly - Install
Install the brush holder assembly.


6. End Cover - Install
Install the end cover.


A/T

1. Switch Plunger and Gear Plunger - Install
Install the switch plunger (A) and the gear plunger (B).


2. Internal Gear - Install
Install the internal gear.


3. Brush Holder Assembly - Install
1.
Install the brush holder assembly.
2.
Install the moving contact (A), contact spring (B), and push nut (C).
NOTE: Always use a new moving contact, contact spring, and push nut.

4. Brush Spring - Install
1.
Install the brushes into the brush holder.
NOTE: To seat the new brushes, slip a strip of?500 or ?600 sandpaper, with the grit side up, between the commutator and each brush, and smoothly rotate the armature (A). The contact surface of the brushes will be sanded to the same contour as the commutator.
2.
While squeezing a brush spring (B), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (C, D, and E).

5. Armature Housing - Install
Install the armature housing.


6. End Cover - Install
Install the end cover.