Starter Overhaul (M/T)

Starter Overhaul

M/T model

Disassembly/Reassembly





Brush Holder Removal

1. Remove the starter. Removal and Replacement

2. Disconnect the motor wire from the M terminal, Testing and Inspection and remove the end cover.

3. Place a plastic pipe with an outside diameter of 28.5 mm (1.12 in.) 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 it with an emery cloth or a lathe to the specifications in step 8, or recondition with #500 or #600 sandpaper (B).






8. Check the commutator diameter. If the diameter is below 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. 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.






12. 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 or vibrates while the core is turned, the armature is shorted. Replace the armature.






13. 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.






Overrunning Clutch Inspection

14. Slide the overrunning clutch along the shaft.
Replace it if it does not slide smoothly.

15. Rotate the overrunning clutch (A) both ways. If it does not lock in either direction, or it locks in both directions, replace it.

16. 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.






Starter Brush Inspection

17. Remove the brush holder cap (A), then remove the brushes (B).






18. Measure the brush length. If it is not within the service limit, replace the brush holder assembly.










Starter Brush Holder Test

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






Starter Reassembly

20. Reassemble the starter in the reverse order of disassembly.

21. Install the starter end cover (A) to retain the brush holder (B).