Inspect
Check there is continuity between commutator segments – use ohmmeter.
Replace armature if there is open circuit.
Inspect
Check there is open circuit between commutator and shaft.
Check also there is open circuit between commutator and armature core – use ohmmeter.
Replace armature if there is continuity.
Inspect
Check there is no short circuit in armature winding – use suitable test equipment.
Replace armature if armature winding is defective.
Measure
Runout of the armature core and commutator – use dial gauge.
Replace armature if runout exceeds:
- 4JA1T/4JA1TC engine - 0.05 mm.
- 4JG2T engine - 0.10 mm.
Inspect
Commutator for wear.
Recut surface of commutator if necessary – turn at speed of 2000-3000 rpm. Minimum diameter:
- 4JA1T/4JA1TC engine - 34 mm
- 4JG2T engine - 36.5 mm.
Remove copper burrs from commutator after recutting.
Caution
Do not damage insulation.
If necessary smooth surface of commutator after removing burrs – use fine emery cloth (P500 to 600) then a buffing cloth.
Measure
Diameter of commutator.
Replace commutator if diameter is less than:
- 4JA1T/4JA1TC engine - 34 mm.
- 4JG2T engine - 36.5 mm.
Measure
Depth of insulation below surface of commutator.
Remove insulation to achieve correct depth of not less than 0.2 mm if necessary – use steel saw; ensure saw is kept level to produce slot of even depth and width.
- Incorrect
- Correct.
Measure
Carbon brush length.
Replace if below:
- 4JA1T/4JA1TC engine - 9.5 mm.
- 4JG2T engine - 11.0 mm.
Inspect
Check insulation between brush holder and base – use ohmmeter.
Replace if there is continuity.
Brush springs.
Inspect
Solenoid switch for continuity of shunt coil between terminal S and solenoid switch body - use ohmmeter.
Replace solenoid switch if there is no continuity.
Inspect
Solenoid switch for continuity of series coil between terminals S and M - use ohmmeter.
Replace solenoid switch if there is no continuity.
Inspect
Contact of solenoid switch for continuity – use ohmmeter.
With plunger facing downward push down on solenoid switch and check continuity between terminals B and M.
Replace solenoid switch if there is no continuity.
Inspect
Check there is no continuity between brush of field winding and stator body - use ohmmeter.
Check there is continuity between brush of field winding and C terminal of lead wire to solenoid switch.
Replace starter if field winding is short circuited to stator body is open circuit or is burnt or charred.
Inspect
Check pinion rotates smoothly in drive direction by hand pinion must not rotate in reverse direction.
Replace pinion if pinion rotates in both directions.
Inspect
Bearings for wear and damage.
