Starter

Pro Technician >>STARTER OVERHAUL
Outline Outline
(1/2)
(1/1)
Removal Components
1. Disconnect Battery Negative (-) Terminal Cable
(1/2)
(1/1)
Removal Components
2. Remove Starter
(1/2)
(1/1)
Disassembly Components
1. Remove Magnet Starter Switch Assembly
Magnet starter switch
Drive lever
(1/2)
(1/1)
2. Remove Starter Yoke Assembly
End cover
Starter housing
Starter yoke
(1/2)
(1/1)
3. Remove Starter Brush Spring
Plate
Brush holder insulator

Spring
(1/2)
(1/1)
4. Remove Starter Armature Assembly
Starter armature
(1/2)
(1/1)
5. Remove Starter Clutch Sub-Assembly
Snap ring
Starter clutch Stop collar
(1/
(1/2)
1)
Disassembly Remove Magnet Starter Switch Assembly
1. Disconnect lead wire 2. Remove magnet starter switch assembly
Lead wire Magnetic starter switch

Starter
housing
Plunger
hook
Drive lever
(1/
(1/2)
1)
Disassembly Remove Starter Yoke Assembly
1. Remove starter yoke assembly
Drive lever
Starter housing
Starter yoke
End cover
(1/
(1/2)
1)
Disassembly Remove Starter Brush Spring
1. Remove starter brush spring
(1/
(1/2)
2)
Plate
Claw
Claw
(1/
(1/2)
2)
Brush Brush spring
(2/
(1/2)
2)

Brush spring
(2/
(1/2)
2)
Brush holder
insulator
(2/
(1/2)
2)
Disassembly Remove Starter Clutch
1. Remove starter clutch
Cloth Vise
(1/
(1/2)
1)
(1)
Cloth Vise
(1/
(1/2)
1)
Snap ring
(1/
(1/2)
1)
Stop collar
Starter clutch
Armature shaft
(1/
(1/2)
1)
Inspection Components
(1/2)
(1/1)
Inspection Inspect Starter Armature Assembly
(1/2)
(1/6)
1. Visual inspection 2. Cleaning
SERVICE HINT:
Visual Check
SERVICE HINT: (1/2)
(2/6)
Cleaning /Washing
3. Starter armature insulation and continuity check
Armature coil Armature Commutator

core
core
Armature
shaft
No continuity
(1/2)
(3/6)
3. Starter armature insulation and continuity check
Armature Commutator
Armature coil Armature
core
Armature
shaft
Continuity
(1/2)
(3/6)
4. Commutator circle runout inspection
SERVICE HINT:
Shaft Runout Inspection
(1/2)
(4/6)
5. Inspect outside diameter of commutator
SERVICE HINT:
Measuring
(1/2)
(5/6)
6. Inspect under cut depth
SERVICE HINT:
Measuring
(1/2)
(6/6)
Inspection Inspect Field Coil
1. Inspect field coil
Brush lead (Group A)

Armature
Continuity
Lead wire Brush lead

(Group B)
Field coil
Lead wire Starter yoke

Brush lead
(Group B) Starter yoke
(1/2)
(1/1)
Inspection Inspect Field Coil
1. Inspect field coil

No Armature
continuity
Lead wire
Brush lead
Field coil (Group B)
Starter
yoke
Lead wire

Starter yoke Brush lead (Group B)
(1/2)
(1/1)
Inspection Inspect Brush
1. Inspect brush
SERVICE HINT:
Measuring
(1/2)
(1/1)
REFERENCE:
Replace Brush
Inspection Inspect Starter Clutch Sub-Assembly
1. Inspect starter clutch operation
Free
Lock
(1/2)
(1/1)
Inspection Inspect Magnet Starter Switch Assembly
1. Inspect magnet starter switch operation
(1/2)
2. Inspect magnet starter switch continuity
Terminal 30
Terminal 50
Hold-in coil
Switch body
Pull-in coil Terminal C
Terminal C
Terminal 50 Continuity
(1/2)
(2/2)
2. Inspect magnet starter switch continuity
Terminal 30
Terminal 50
Hold-in coil
Pull-in coil
Switch body Switch body
Terminal C
Continuity
Terminal 50
(1/2)
(2/2)
Reassembly Components
1. Install Starter Clutch Sub-Assembly
Snap ring
Starter clutch Stop collar
(1/2)
(1/1)
2. Install Starter Armature Assembly
Starter armature assembly
(1/2)
(1/1)
3. Install Starter Brush Spring
Plate

Spring
(1/2)
(1/1)
4. Install Starter Yoke Assembly
End cover
Starter housing
Starter yoke
(1/2)
(1/1)
5.Install Magnet Starter Switch Assembly
Drive lever
(1/2)
(1/1)
Reassembly Install Starter Clutch Sub-Assembly
1. Install starter clutch sub-assembly
Grease
(1/2)
Starter clutch
(1/2)
Stop collar
(1/2)
Snap ring
Stop collar
SERVICE HINT:
Snap Ring
(1/2)
Snap Stop
ring collar
Stop collar
Starter clutch
(1/2)
(2/2)
Reassembly Install Starter Brush Spring
1. Install starter armature assembly on starter yoke 2. Install starter brush spring
Aluminium
plate
Vise
(1/2)
(1/1)
2. Install starter brush spring
(1/2)
(1/1)

Brush spring
Brush spring
(1/2)
(1/1)
Brush Brush
spring
(1/2)
(1/1)
Plate
Claw
Claw
(1/2)
(1/1)
Reassembly Install Starter Yoke Assembly
1. Install starter yoke assembly
Drive lever
Grease
Starter housing
Starter yoke
End cover
(1/2)
(1/1)
Reassembly Install Magnet Starter Switch Assembly
1. Install magnet starter switch 2.Connect lead wire

Starter housing
Lead wire
Plunger hook
Drive lever
(1/2)
(1/1)
Test Components
Pull-in test
(1/2)
(1/1)
Test Components
Hold-in test
(1/2)
(1/1)
Test Components
Check pinion gear clearance
(1/2)
(1/1)
Test Components
No-load test
(1/2)
(1/1)
Test Pull-In Test
1. Pull-in test
Starter body Terminal 30 Pinion gear

Terminal 50 Test lead A
Terminal C Hold-in coil (1/2)
(1/1)
Field coil lead wire Pull-in coil

Test Hold-In Test
1. Hold-in test

(1/1)

Test Check Pinion Gear Clearance
1. Check pinion gear clearance
SERVICE HINT:
Measuring
(1/2)
(1/1)
Test Pinion Return Test
1. Pinion return test

(1/1)

Test No-Load Test
1. No-load test
Starter body
Terminal 50
Terminal C (1/2)
Terminal 30
Test No-Load Test
1. No-load test
Starter body
Terminal 30
Terminal C
Terminal 50
(1/2)
(2/2)
Installation Components
1. Install Starter
(1/2)
(1/1)
Installation Components
2. Connect Battery Negative (-) Terminal Cable
(1/2)
(1/1)
Installation Final inspection
Ignition switch
Starter
(1/2)
(1/1)

Starter

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Starter

Uploaded by

Copyright:

Available Formats

Pro Technician >>STARTER OVERHAUL

1. Disconnect Battery Negative (-) Terminal Cable

1. Remove Magnet Starter Switch Assembly

Magnet starter switch

2. Remove Starter Yoke Assembly

3. Remove Starter Brush Spring

Brush holder insulator

4. Remove Starter Armature Assembly

5. Remove Starter Clutch Sub-Assembly

1. Disconnect lead wire 2. Remove magnet starter switch assembly

Lead wire Magnetic starter switch

1. Remove starter yoke assembly

1. Remove starter brush spring

1. Remove starter brush spring

1. Remove starter brush spring

Brush Brush spring

1. Remove starter brush spring

Brush holder insulator

1. Remove starter brush spring

1. Remove starter clutch

1. Remove starter clutch

1. Remove starter clutch

1. Remove starter clutch

1. Visual inspection 2. Cleaning

3. Starter armature insulation and continuity check

Armature coil Armature Commutator

3. Starter armature insulation and continuity check

4. Commutator circle runout inspection

5. Inspect outside diameter of commutator

6. Inspect under cut depth

1. Inspect field coil

Brush lead (Group A)

Lead wire Brush lead

Brush lead (Group A)

1. Inspect field coil

Brush lead (Group A)

Brush lead (Group A)

1. Inspect starter clutch operation

1. Inspect magnet starter switch operation

2. Inspect magnet starter switch continuity

Pull-in coil Terminal C

2. Inspect magnet starter switch continuity

1. Install Starter Clutch Sub-Assembly

2. Install Starter Armature Assembly

Starter armature assembly

3. Install Starter Brush Spring

Brush holder insulator

4. Install Starter Yoke Assembly

5.Install Magnet Starter Switch Assembly

Magnet starter switch

1. Install starter clutch sub-assembly

1. Install starter clutch sub-assembly

1. Install starter clutch sub-assembly

1. Install starter clutch sub-assembly

1. Install starter clutch sub-assembly

2. Install starter brush spring

Brush holder insulator

2. Install starter brush spring

Brush holder insulator

Brush holder insulator

2. Install starter brush spring

Brush holder insulator

2. Install starter brush spring

1. Install starter yoke assembly