Starter Overhaul

1


2908_4.0_enu_14071514_6.0

enu_12714524_1.0
Replace
*1
Do not wipe off the special grease applied.
*2
These parts have inspection items.

1. End Cover - Remove


2. Armature Housing - Remove


3. Armature - Remove


4. Terminal - Remove


5. Brush Spring - Remove


6. Moving Contact - Remove


7. Brush Holder Assembly - Remove


8. Planetary Gear Assembly - Remove


9. Switch Shaft - Remove


10. Switch Plunger - Remove


11. Gear Plunger - Remove


Armature

1. 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):
0.40?0.50 mm (0.0157?0.0197 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 of the 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.

Brush Holder

1. Brush Holder Assembly - Inspect
1.
Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.
2.
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)

Planetary Gear Assembly

1. Planetary Gear - Inspect
1.
Check the planetary gears (A), the gear shaft (B), and the internal ring gear (C). Replace them if they are worn or damaged.

Gear Cover Assembly

1. Overrunning Clutch - Inspect
1.
Hold 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.
Hold 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: enu_12713377_2.0 Where icon is shown, click for further information.


1


2908_4.0_enu_14071527_6.0

enu_12713377_2.0
Detailed information, notes, and precautions
enu_12714505_1.0
Torque: N·m (kgf·m, lbf·ft)
enu_12714524_1.0
Replace
*1
Do not wipe off the special grease applied.
*2
These parts have inspection items.

1. Gear Plunger - Install


2. Switch Plunger - Install


3. Switch Shaft - Install


4. Planetary Gear Assembly - Install


5. Brush Holder Assembly - Install


6. Moving Contact - Install


7. Terminal - Install


8. Armature - Install

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 turn the armature. The contact surface of the brushes will be sanded to the same contour as the commutator.

9. Brush Spring - Install
1.
While squeezing a spring (A), insert it in the hole on the brush holder, and push it until it bottoms. Repeat this for the other three springs (B, C, and D).

10. Armature Housing - Install


11. End Cover - Install