Starter Overhaul: Disassembly/Reassembly

Fig 1: Exploded View Of Starter Assembly Components

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Brush Holder Removal 

1. Remove the starter (see STARTER REMOVAL AND INSTALLATION  ).
2. Disconnect the wire from the M terminal, and remove the end cover.
3. Place a 29.4 mm (1.16 in.) outside diameter plastic pipe on the armature.
   Fig 2: Placing Outside Diameter Plastic Pipe On Armature

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4. Move the brush holder (A) up to the pipe (B) while holding the pipe so the brushes do not pop out from the holder.
   Fig 3: Moving Brush Holder Up To Pipe

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   Armature Inspection and Test 

5. Disassemble the starter as shown in Fig 1 at the beginning of this procedure.
6. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 4: Inspecting Armature For Wear Or Damage

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7. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).
   Fig 5: Checking Commutator Surface

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8. Check the commutator diameter. If the diameter is out of the service limit, replace the armature.

   Commutator Diameter 

   • Standard (New): 29.3-29.5 mm (1.154-1.161 in.) 
   • Service Limit: 28.8 mm (1.134 in.) 
   Fig 6: Checking Commutator Diameter

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9. Measure the commutator (A) runout.
   • If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips between the segments.
   • If the commutator runout is not within the service limit, replace the armature.

   Commutator Runout 

   • Standard (New): 0.05 mm (0.002 in.) max. 
   • Service Limit: 0.1 mm (0.004 in.) 
   Fig 7: Measuring Commutator Runout

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10. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too shallow, too narrow, or V-shaped (D).

    Commutator Mica Depth 

    • Standard (New): 0.40-0.50 mm (0.016-0.020 in.) 
    • Service Limit: 0.20 mm (0.008 in.) 
    Fig 8: Checking Mica Depth

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11. Check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
    Fig 9: Checking Continuity Between Segments Of Commutator

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12. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attached to the core or vibrates while the core is turned, the armature is shorted. Replace the armature.
    Fig 10: Placing Armature On Armature Tester

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13. Use an ohmmeter to check for continuity betweeen the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.
    Fig 11: Checking Continuity Between Commutator & Armature Coil Core

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    Starter Brush Inspection 

14. Measure the brush length (A). If it is shorter than the service limit, replace the brush holder assembly.

    Brush Length 

    • Standard (New): 7.7-8.0 mm (0.30-0.31 in.) 
    • Service Limit: 0.9 mm (0.04 in.) 
    Fig 12: Measuring Brush Length

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    Starter Brush Holder Test 

15. Check for continuity between the (+) brush (A) and (-) brush (B). If there is continuity, replace the brush holder assembly.
    Fig 13: Checking Continuity Between (+) Brush & (-) Brush

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    Planetary Gear Inspection 

16. Check the planetary gears (A) and ring gear (B). Replace them if they are worn or damaged.
    Fig 14: Checking Planetary Gears & Ring Gear

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    Overrunning Clutch Inspection 

17. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
18. Rotate the overrunning clutch (A) in both directions. It should lock and move upward in one direction and rotate smoothly in the other direction. If it does not lock in either direction or if it locks both directions, then replace it.
    Fig 15: Rotating Overrunning Clutch

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19. If the starter drive gear (B) is worn or damaged, replace the overrunning clutch assembly; the gear is not available separately. Check the condition of the idler gear and drive plate ring gear to see if the starter drive gear teeth are damaged.

    Starter Reassembly 

20. Install the armature into the housing.
21. Place the brush holder assembly on the armature, then move the brush holder (A) down to the armature.
    Fig 16: Moving Brush Holder Down To Armature

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22. Install the end cover to retain the brush holder.
    Fig 17: Installing End Cover To Retain Brush Holder

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