1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity
bet\~een the ;;egments of the commutator.
If there is no continuity between any segments, re- place the umature.
2 • . INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no cc-.ntinuity between the commutator and armature coil core.
If there is continuit-y, replace the armature.
Commutator
1. INSPECT COMMUTATOR FOR'DIRTY AND BURNT SURFACES
If the surface is dirt-y or burnt, correct with sandpapsr (No.400) or a lathe.
2. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Piace tha <•om mutator on V -0!ccics.
(b)-ã Usin;J a dial gauge, measure tha circle run out;
3.
Mexlmum circle runout:
0.05 mm (0.0020 ln.)
If the circle runout is greater1h1m maximum, correct it on a lathe.
INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diam- eter.
Standard diameter:
28 mm (1.10 ln.) Minimum diameter:
27 mm (1.06 ln.)
If the diameter is less than minimum, replace the armature.
~ i '
I :I
ST-6
Continuity
No coiitinuit\'
STARTING SYSl'EM -STARTER
ST0040 1
l
4. INSPECT UNDEi)C:..'T DEPTH
Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.
Standard undercut depth:
0.6 mm (0.024 in.) Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum. correct it
wi~h a hacksaw blade.
Field Frame (Field Coil)
1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter. check that there is continuity between the lead wire and field coil brush lead.
If> there is no continuity, r~place the field frame.
2. INSPECT FIELD COIL GROUND
Using an ohmmeter, check that there is no continuity between the field coil end and field frame:
If there .is continuity, repair or replace tho field frame.
Brushes
INSPECT BRijSIJ LENGTH
Using vernfer calipers, measure the brush length.
Stondord length:
14.0 mm (0.551 ln.) Minimum longth:
9.0 mm (0.354 in.)
ff thq Jqngth k Jqu lh;m minimum. mplilGii !hr. /;ru~l.
holder and filed frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
ãTake the pull scale reading the instant the brush spring separates from the brush.
Spring installed load:
8.8'- 17.7 N (0.9 - 1.8 kgf, 2.0 - 4.0 lbf)
.. r
-ã
<
. STARTING.SYSTEM- STARTER
__ ; •. ---'-~--,
- .
•.
•' ! -ã .
,. .
•
i;
No continuity
- - - " " ' - " I
Contjnuity
STOC:67
Terminal 50 Terminal C
P10134
Brush'Hoider
INSPECT BRuSH HOLDER INSULATION
Usinãg an ohmmeter, check that there is no continuity between the positive{+) and negative(-) brush hol- ders.
If there is continuity, repair or replace the brcsh holder.
Clutch and Gears .
1.
2 .
INSPECT GEAR TEETH
Check the gear teeth on tha planetary gear.- internal gear and starter clutch for woar or damage.
If tl;le gear is damaged, repiBce it.
If the starter clutch teeth are damaged; replace the starter clutch and also inspect the fl~wheel ring gear for wear or damage.
INSPECT STARTER CLUTCH
Rotate the clutch pinion gear clockwise and check that it turns freely.
Try to rotate the clutch pinion gear counterclockwise and check that it locks.
If necessary, replace the starter clutch.
Magnetic Switch
1. INSPECT PLUNGER
Push in the plunger and replace it.
Check that it returns quickly to it:? original position.
If necessary, replace the magnetic> swit!:h.
2. DO PULL--'I.N COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity. replace the magnetic switch.
ãt.
. ' ~
'i f
I:
.,•,.
ST-8 STARTING SYSTEMã,... STARTER.
--- ~
~ST e:i--~
"--' - Yf - I
~" fy)
/
'
3. DO .HOLD..., IN COIL OPEN CIRCUIT TEST
. I • •
Using M ohmmeter, check that there is continuity between terminal 50 and the switch body. ã If there is no continuity, replace the magnetic switch. ã
. ,
Planetary Shaft and Center Bearing
1. INSPECT PLANETARY SHAFT AND CENTER BEAR- ING
(a) Using a micrometer, measure the outer diameter of the, surface in contact with the center bearing of the planetary shaft.
Standard shaft diameter:
14.980- 15.000 mm (0.5898- 0.5906 in.)
(b) Using a caliper gauge, measure the inside diameter of the center bearing.
Center boadng Inside diameter:
15.008 - 15.050 mm (0.5908 - 0.5925 in.) (c) Subtract the planetary shaft diameter from the bear-
ing inside diameter measurement.
Standard center bearing oil clearance:
0.01 - 0.06 mm (0.0004 - 0.0024 in.) Maximum cantor bearing oil cloarance:
0.2 mm (0.0078 ln.)
If the clearance is greater than maximum, replace the planet carrier shaft and center bearing.
2. lF NEC!:SSARY, REPLACE CENTER BEARING (a) Using SST and .Press, press out the center bearing.
SST 09221-25025 (09221-00090)
(b) Using SST and a press, press in a new center bearing to the posi.tion shown in the illustration.
•
....
ã-
SST 09221-25025 (09221-00071) •
•
- ' '
• •
ã'
-
STARTING. SYSTEM:....ã STARTERã ST-9
' '
Shock Absorber
Hollow Protrusion
SToo-17
ã liollow
STC647
(j Planetar~ã Shaft
f
Plate Washer
)671 Zl~l
sroon
ã(c) Align the hollow of tha internal gear with the protru- sion inside the shock absorber, and remove the inter- rial gear. ã
STARTER ASSEMBLY
1.
HINT: Use high temperature-resistant grease to lu- bricate the bearings and sliding parts when assembl- ing the starter.
INSTALL INTERNAL GEAR AND PLANETARY SHAFT
(a) Apply grease to the internal gear touching the sock absorber and planetary gears.
(b) Align the hollow of the internal gear with the protru- sion inside the shock absorber.
(c) Insert and turn the internal gear 5o that it interlocks with the shock absorber.
(d) (e)
(f) (g)
: 2.
(a) (b)
Apply turbine oil with additives to thA c&nter bearing.
Apply grease to the plate washer. and install it to the plar.atary shaft
Install theãplanetary shaft to the shock absorber.
Using snap ring plior~. install the plato washer and snap ring.
INSTALL STARTER CLUTCH
Apply grease to the bushing and splir.e of the starter clutch and stop collar.
Place the starter clutch anãd stop collar on the planoã
tary shaft.
..
ST-10
STARTJNG.SYSTEM - STARTEtl
ST007J
t :
ãã~.
ST07<11
(c) Apply. grease to the snap ring, and instal! it to the planetary .shaft gro.ove.
(d) Using a vise, compress the snap ring.
(e) Hold the starter clutch, tap the planetary shaft and install the stop collar onto the Sflap ring with a plastic -facod hammer.
3. INSTALL PLANETARY GEARS
(a) Apply grease to the planetary. gears and flange pin parts of the planetary shaft.
(b) Install the plate washer and 3 planetary gears.
(c) Align the cutout of the plate With the protrusion insida the shock absorber, and install the plate.
4. INSTALL DRIVE LEVER AND STARTER CLUTCH WITH SHOCK ABSORBER
(a) Apply turbine cil with additives to tlie bearing ot 1he starter housing.
(b) Apply grease to th& drive levor touching the starter pivot part of the drive levsr.
(c) Install tho drive lever to the starter clutch.
(d) Align the protrusion of the shock absorber with the 0utout of the starter hol!sing and install them.
. .
•
..
.ã
•
. .• . ... ..
. .
ã.
i
iT0727
R I 88.(
STARTING SYSTEM - STAR.TER ST-11
"""
Protrusion
= I I
ST0742
5.
6.
7.
INSTALL 2 NEW 0-RJNGS TO FJELD FRAME PLACE ARMATURE INTO FIELD FRAME INSTALL BRUSH HOLDER
(a) Place the brush holder in position on ths armature.
(b) Using a screwdriver. hold the brush spring back. a.1d connect the brush into tho brush holder. ' Connect the 4 ãbrushes.
HINT: Check that positive(+) lead wires are not gro- unded.
8. INSTALL COMMUTATOR ENO FRAME
(a) Apply turbine oil with additives to t~e bearing of the end frame.
(b) Install the end frame with 2 new screws with 0-:-- rings.
NOTICE: To avoid interference between tho brush holder and tho dust protector, pull tho commutator ~rid frame away at an angle.
9. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
(a) Align the cutout of the field frame with the protrusion of the shock absorber.
(b) Install tho field frame and arrnaturo assnmbly with the 2 through bolts.
10.
(a) (b)
(c) (d)
INSTALL MAGNETIC SWITCH
Install the plunger cover to the magnet:c switch.
Ha11g the pltrnpE!r ol tho magn~ti.:: ,~witch to the drive levsr from the upper side.
Install ths magnetic switch with the 2 nuts ..
Connect the lead wire to th~ terminal, And install the nut.
(e) Install the magnetic switch cover with the nut.
11. INSTALL MAGNETIC SWITCH COVER