Disassembly and Reassembly

INSPECTION (AFTER REMOVAL)

PINION GAP ADJUSTMENT
1. Disconnect the wire from the M-terminal.

Fig. 4 Pinion Gap Adjustment (Part 1 Of 3):

2. Connect a 12 V battery between the S-terminal and the M-terminal.
3. Set the switch to "ON", and the pinion will move out.


CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.





4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge. If the pinion gap is out of specification, adjust by adding or removing washers between the solenoid and the front bracket.

Standard value:
Pinion Gap : 0.5-2.0 mm (0.0197-0.079 in.)

SOLENOID PULL-IN TEST
1. Disconnect the connector from the M-terminal.




2. Connect a 12 V battery between the S-terminal and M-terminal.


CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.


3. If the pinion moves out, the pull-in coil is good. If it doesn't replace the solenoid.

SOLENOID HOLD-IN TEST
1. Disconnect the connector from the M-terminal.




2. Connect a 12 V battery between the S-terminal and the body.


CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.


3. If the pinion remains out, everything is in order. If the pinion moves in, the hold-in circuit is open. Replace the magnetic switch.

SOLENOID RETURN TEST
1. Disconnect the connector from the M-terminal.




2. Connect a 12 V battery the M-terminal and the body.


CAUTION: This lest must be performed quickly (in less than 10 seconds) to prevent the coil from burning.


3. Pull out the pinion and then release it. If the pinion returns quickly to its original position, everything is in order. If it doesn't replace the solenoid.

PERFORMANCE TEST (NO-LOAD)




1. Make the no-load circuit test as shown.
2. After adjusting the rheostat until the battery voltage shown on the voltmeter reads 11.5 Volts, confirm that the maximum amperage draw is with in the specifications and that the starter motor turns smoothly and freely.

Current : 60 A or less

DISASSEMBLY
To remove the overrunning clutch from the armature shaft, the stop ring must be removed.




Move the stop ring toward the pinion and remove the snap ring, now the stop ring can be removed from shaft.

INSPECTION (AFTER DISASSEMBLY)




ARMATURE COIL GROUND TEST
Using an ohmmeter, check to make sure that there is no continuity between the commutator and the armature coil core. If there is continuity, replace armature assembly.




ARMATURE COIL SHORT-CIRCUIT TEST
Test the armature coil in a growler. Replace the coil if there are signs of a short. If the blade attached to the core vibrates while the core is turned, the armature is shorted.




ARMATURE COIL OPEN-CIRCUIT TEST
Using an ohmmeter, check for continuity between the commutator segments. If there is no continuity, the commutator segments are open. Replace the armature assembly.




FIELD COIL OPEN-CIRCUIT TEST
Using an ohmmeter, check the filed coil for continuity. If there is no continuity, the field coil is open. Replace the field coil assembly.




FIELD COIL GROUND TEST
With the field coil mounted to the yoke, check for continuity between the field coil and the yoke using an ohmmeter. If there is continuity, replace the field coil.




BRUSH
A brush worn down to the wear limit line should be replaced.




BRUSH HOLDER
Check for continuity between the (+) side brush holder and brush holder base. If there is continuity, replace the holder assembly.

OVERRUNNING CLUTCH
Inspect the pinion and spline teeth for wear or damage. Replace if damaged. Also inspect the flywheel ring gear for damage.




Rotate the pinion. It should turn freely in a clockwise direction, and lock when turned counterclockwise.

BRUSH REPLACEMENT
1. Remove the worn brush while taking care not to damage the pigtail.




2. Sand the pigtail end with sandpaper to ensure a good soldering joint.
3. Solder the end of the pigtail.

REASSEMBLY

1. Install the overrunning clutch to the front end of the armature shaft.




2. Install the stop ring and the snap ring from the front end of the armature shaft. Push the stop ring all the way toward the snap ring.




3. When the lever is mounted to the front bracket, pay attention to its direction. If is mounted in a reverse direction, the pinion will remain in an outward position and fail to operate properly