Starter, Disassemble
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Nut and cable from terminal M of solenoid switch.
| Solenoid switch assembly from starter - two bolts. | |||
|---|---|---|---|
| .P. U2500.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Torsion spring, plunger, shim and solenoid switch. | |||
| .P. U2501.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
Motor assembly from pinion case - through bolts (1).
| Rear cover - screws (2). | |||
|---|---|---|---|
| .P. U2502.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
Brush holder from stator assembly - raise brush spring and detach brushes from commutator surface, then pull off brush holder.
| Armature from stator. | |||
|---|---|---|---|
| .P. U2503.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Armature, yoke assembly, bearing retainer, remove three screws, pinion assembly, bearing holder, bearing, shift lever. | |||
| .P. U3447.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Pinion assembly, remove clip using screwdriver. | |||
| .P. U2506.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Pinion stopper (1), return spring (2), pinion shaft (3), clutch (4). | |||
| .P. U2468.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
Bearing from pinion case.
| Large bearing with hollow shaft from clutch - use suitable sleeve. | |||
|---|---|---|---|
| .P. C7191.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Hollow shaft from large bearing - use suitable sleeve. | |||
| .P. C7192.tif | 9 | 7,5 | tiff;; |
| .D. ICON03.tif | 0,75 | 0,75 | tiff;; Disassemble |
| Bearings from armature - use suitable puller. | |||
| .P. D1075.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
| Check for continuity between commutator segments, replace armature if no continuity. | |||
| .P. U2252.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Check for no continuity between commutator and shaft, check also for no continuity between commutator and armature core, armature core and shaft.
| Replace armature if there is continuity. | |||
|---|---|---|---|
| .P. U2508.tif | 9 | 7,5 | tiff;; |
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Runout of the armature core and commutator - use dial gauge.
| Replace armature if runout exceeds - 0.1 mm/0.004 in. | |||
|---|---|---|---|
| .P. U2509.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Commutator for wear.
Recut surface of commutator if necessary - turn at speed of 2000-3000 rpm. Minimum diameter - 36.5 mm/1.437 in.
Remove copper burrs from commutator after recutting.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Do not damage insulation.
| If necessary smooth surface of commutator after removing burrs - use fine emery cloth (P500-600), then a buffing cloth. | |||
|---|---|---|---|
| .P. C7185.tif | 9 | 7,5 | tiff;; |
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Diameter of commutator.
| Replace commutator if diameter is less than - 36.5 mm/1.437 in. | |||
|---|---|---|---|
| .P. U2507.tif | 9 | 7,5 | tiff;; |
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Depth of insulation below surface of commutator.
| If necessary remove insulation to achieve a depth of not less than 0.2 mm/0.008 in. - use steel saw; ensure saw is kept level to produce slot of even depth and width. | |||
|---|---|---|---|
| .P. U6190.tif | 9 | 7,5 | tiff;; |
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Carbon brush length.
| Replace if below 11.0 mm/0.43 in. | |||
|---|---|---|---|
| .P. U2511.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Check for continuity between brush holder and base, replace if there is continuity.
| .D. ICON07.tif | 0,75 | 0,75 | tiff;; Measure |
Brush spring tension.
| Replace if not to specification. | |||
|---|---|---|---|
| .P. U2512.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
| Solenoid switch for continuity of shunt coil between terminal S and solenoid switch body, replace solenoid switch if no continuity. | |||
| .P. U3448.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
| Solenoid switch for continuity of series coil between terminals S and M, replace solenoid switch if no continuity. | |||
| .P. U3449.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Solenoid switch for continuity of contacts.
| With plunger facing downward push down on solenoid switch and check continuity between terminals B and M, replace solenoid switch if no continuity. | |||
|---|---|---|---|
| .P. U3450.tif | 9 | 7,5 | tiff;; |
| .D. ICON06.tif | 0,75 | 0,75 | tiff;; Inspect |
Check pinion rotates smoothly in drive direction by hand, pinion must not rotate in reverse direction.
Replace if pinion rotates in both directions.
| Bearings for wear and damage. | |||
|---|---|---|---|
| .P. U2513.tif | 9 | 7,5 | tiff;; |