Starter Cleaning, Inspection and Testing
TOOLS REQUIRED^ J 544-01 Tension Scale
^ J 8001 Dial Indicator
^ J26900-13 Magnetic Base
^ J 26900-5 Vernier Caliper
^ J 39200 Digital Multimeter
NOTICE: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation.
1. Clean all starter motor pants.
2. Remove dirt and burn marks from the commutator end (2) of the armature (1) by sanding with a #300 or #400 grit sandpaper. Wipe the pants with a clean shop cloth.
3. Place the armature onto a pair of V-blocks (1). Measure the commutator run-out using a J 8001 with a J 26900-la If the run-out exceeds the maximum, replace the armature.
STANDARD COMMUTATOR RUN-OUT
0.05 mm (0.002 in) or less
MAXIMUM COMMUTATOR RUN-OUT
0.40 mm (0.016 in)
4. Measure the outside diameter of the commutator using a J 26900-5. If the outside diameter is less than the minimum, replace the armature (1).
STANDARD COMMUTATOR DIAMETER
29.4 mm (1.157 in)
MINIMUM COMMUTATOR DIAMETER
28.8 mm (1.134 in)
5. Measure the commutator insulation (1) depth. If the insulation depth is less than the minimum, replace the armature.
STANDARD COMMUTATOR INSULATION DEPTH
0.5 to 0.8 mm (0.020-0.031 in)
MINIMUM COMMUTATOR INSULATION DEPTH
0.2 mm (0.008 in)
6. Measure the resistance between the armature core (1) and the commutator (2) using a J 39200. If the resistance is 5.0 ohms or less, the armature is grounded and must be replaced.
7. Measure the resistance between the commutator segments using J 39200. If resistance is greater than 5.0 ohms at any test point, there is an open circuit in the commutator and the armature must be replaced.
8. Measure the resistance between the positive brush holder and the negative brush holder using the J 39200. If the resistance is 5.0 ohms or less, the brush holder is grounded and must be replaced.
9. Measure the brush (1) length using the J 26900-& If the brush length is less than the minimum, replace the brush.
STANDARD BRUSH LENGTH
17.5 mm (0.67 in)
MINIMUM BRUSH LENGTH
12.0 mm (0.47 in)
10. Inspect the brush springs for corrosion or damage. Also Inspect the brush holder and the insulation on the positive plates for wear. Replace components as necessary.
11. Measure the brush spring (2) tension using a J 544-01. If the brush spring tension is less than the minimum, replace the brush spring.
STANDARD BRUSH SPRING TENSION
1.9kg (4.19 lbs)
MINIMUM BRUSH SPRING TENSION
0.7 kg (1.54 lbs)
12. Measure the starter solenoid pull-in coil resistance between terminal S (3) and terminal M using the J 39200. If the resistance is greater than 5.0 ohms the pull-in coil is open and the starter solenoid must be replaced.
13. Measure the starter solenoid hold-in coil resistance between terminal S (3) and the solenoid case using the J 39200. It the resistance is greater than 5.0 ohms, the hold-in coil is open and the starter solenoid must be replaced.
14. Inspect the pinion drive lever (4) for wear. Replace as necessary.
15. Inspect the overrunning clutch (1) for wear, damage or other abnormal conditions. Verify that the clutch locks when turned in the drive direction and rotates smoothly in the reverse direction. Replace as necessary.
16. Inspect the overrunning clutch spine teeth (1) for wear or damage. Replace as necessary.
17. Inspect the armature bushing and bearing (1) for wear and damage. Replace as necessary.
18. Inspect the commutator end bushing for wear and damage. Replace as necessary.
19. Inspect the starter solenoid plunger by pressing the plunger in and releasing it. It the plunger does not return to its original position quickly, replace the starter solenoid (1).
20. Inspect the internal gear assembly (1) and the idle gears (2,3) for wear, damage or other abnormal conditions. Replace as necessary.