Overhaul

OVERHAUL




1. REMOVE REPAIR SERVICE STARTER KIT
a. Remove the nut and disconnect the lead wire from the repair service starter kit.




b. Remove the 2 screws which are used to secure the repair service starter kit to the repair service starter kit.
c. Remove the repair service starter kit.
d. Remove the return spring and the plunger from the repair service starter kit.




2. REMOVE STARTER YOKE ASSEMBLY
a. Remove the 2 through bolts and pull out the starter yoke together with the starter commutator end frame.




b. Remove the starter yoke from the starter commutator end frame.




3. REMOVE STARTER ARMATURE PLATE
a. Remove the starter armature plate from the starter yoke.




4. REMOVE DRIVE HOUSING STARTER BEARING COVER
a. Using a screwdriver, remove the drive housing starter bearing cover.




5. REMOVE STARTER ARMATURE ASSEMBLY
a. Using snap ring pliers, remove the snap ring and the plate washer.
b. Remove the starter armature from the commutator end frame.




6. REMOVE PLANET GEAR
a. Remove the 3 planet gears from the motor terminal starter kit.




7. INSPECT REPAIR SERVICE STARTER KIT
a. Check the plunger.
1. Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the repair service starter kit.




b. Check the resistance.
1. Using an ohmmeter, measure the resistance between terminals 50 and C.

Standard: below 1 Ohm

If the result is not as specified, replace the repair service starter kit.




c. Using an ohmmeter, measure the resistance between terminal 50 and the starter kit body.

Standard: below 2 Ohms

If the result is not as specified, replace the repair service starter kit.




8. INSPECT STARTER ARMATURE ASSEMBLY
a. Check the resistance.
1. Using an ohmmeter, measure the resistance between the segments of the commutator.

Standard: below 1 Ohm

If the result is not as specified, replace the starter armature.




b. Using an ohmmeter, measure the resistance between the segment of the commutator and armature coil core.

Standard: 10 kOhms or higher

If the result is not as specified, replace the starter armature.

c. Check the commutator surface for dirt or burning.
If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.




d. Check the commutator depth.
1. Using vernier calipers, measure the commutator depth.

Standard depth: 3.1 mm (0.122 in.)
Maximum depth: 3.8 mm (0.150 in.)

If the length is greater than the maximum, replace the starter armature assembly.




9. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
a. Check the brush length.
1. Using vernier calipers, measure the brush length.

Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)

If the length is less than minimum, replace the starter commutator end frame.




b. Check the resistance.
1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.

Standard: 10 kOhms or higher

If the resistance is not as specified, repair or replace the starter commutator end frame.




10. INSPECT MOTOR TERMINAL STARTER KIT
a. Check the starter clutch.
1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise. Check that it locks.

If necessary, replace the motor terminal starter kit.




11. INSTALL PLANET GEAR
a. Apply high-temperature grease to the planet gears and pin parts of the planetary shaft.
b. Install the 3 planet gears to the motor terminal starter kit.




12. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply high-temperature grease to the plate washer and the armature shaft.
b. Install the starter armature to the starter commutator end frame.
c. Using snap ring pliers, install the plate washer and a new snap ring.




d. Using vernier calipers, measure the snap ring.

Maximum length: 5.0 mm (0.197 in.)

If the length is greater than the maximum, replace the snap ring.




13. INSTALL DRIVE HOUSING STARTER BEARING COVER
a. Install the drive housing starter bearing cover to the starter commutator end frame.




14. INSTALL STARTER ARMATURE PLATE
a. Align the claw of the armature plate with the groove inside the starter yoke, and install the starter armature plate.




15. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the starter commutator end frame rubber with the groove of the starter yoke.
b. Install the starter commutator end frame to the starter yoke.

NOTE: The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.




16. INSTALL STARTER YOKE ASSEMBLY
a. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.




b. Install the starter yoke with the 2 through bolts.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)




17. INSTALL REPAIR SERVICE STARTER KIT
a. Apply high-temperature grease to the plunger and the hook.
b. Hang the plunger hook of the repair service starter kit to the drive lever hook.
c. Install the plunger and the return spring.




d. Install repair service starter kit with the 2 screws.

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)




e. Connect the lead wire to the repair service starter kit with the nut.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)