Exploded View

Fig 1: Exploded View Of Starter (M/T Model)

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Brush Holder Removal 

1. Remove the starter .
2. Disconnect the motor wire from the M terminal , and remove the end cover.
3. Remove the brush holder (A).
   Fig 2: Identifying Brush Holder

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   Armature Inspection and Test 

4. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.
   Fig 3: Identifying Armature

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5. Check the commutator (A) surface. If the surface is dirty or burnt, resurface it with an emery cloth or a lathe to the specifications in step 6, or recondition with #500 or #600 sandpaper (B).
   Fig 4: Identifying Commutator And Sand Paper

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6. Check the commutator diameter with a digital caliper or dial type caliper. If the diameter is below the service limit, replace the armature.

   Commutator Diameter 

   Standard (New): 28.0- 28.1 mm (1.102- 1.106 in) 

   Service Limit: 27.5 mm (1.083 in) 

   Fig 5: Checking Commutator Diameter With Digital Caliper Or Dial Type Caliper

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7. 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): 0.02 mm (0.0008 in) max. 

   Service Limit: 0.05 mm (0.0020 in) 

   Fig 6: Identifying Commutator

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8. Use a digital caliper or dial type caliper to check the mica depth (A). If the mica depth is below the service limit, replace the armature.

   Commutator Mica Depth 

   Standard (New): 0.4- 0.5 mm (0.016- 0.020 in) 

   Service Limit: 0.15 mm (0.0059 in) 

   Fig 7: Checking Mica Depth Of Armature Slots

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9. Use an ohmmeter to check for continuity between the segments of the commutator. If there is an open circuit between any segments, replace the armature.
   Fig 8: Checking Continuity Between Segments Of Commutator

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10. Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. If the blade is attracted to the core while the core is turned, the armature is shorted. Replace the armature.
    Fig 9: Identifying Armature, Armature Tester And Hacksaw Blade

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11. Use an ohmmeter to check for continuity between 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 10: Identifying Commutator, Armature Coil Core And Armature Shaft

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    Starter Brush Inspection 

12. Remove the brush holder cap (A), then remove the brushes (B).
    Fig 11: Identifying Brush Holder Cap And Brushes

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13. Measure the brush length. Shorter than the service limit, replace the brush holder assembly.

    Brush Length 

    Standard (New): 15.8- 16.2 mm (0.622- 0.638 in) 

    Service Limit: 11.0 mm (0.433 in) 

    Fig 12: Measuring Brush Length With Vernier Caliper

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    Starter Brush Holder Test 

14. Check for continuity between the (+) brushes (A) and the (-) brushes (B). If there is continuity, replace the brush holder assembly.
    Fig 13: Identifying (+) And (-) Brushes

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    Overrunning Clutch Inspection 

15. Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
16. Rotate the overrunning clutch (A) both ways. If it does not lock in either direction, or it locks in both directions, replace it.
    Fig 14: Rotating Overrunning Clutch

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17. 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 flywheel ring gear to see if the teeth are damaged.

    Starter Reassembly 

18. Install the armature in the housing.
19. Set the brushes with the brush spring in the brush holder (A).
    Fig 15: Identifying Brush Holder

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20. Place the brush holder assembly on the armature, then move the brush holder down to the armature.
    NOTE: Keep the brush holder on the armature so the brushes do not come out of the brush holder.
21. Install the end cover (A) to retain the brush holder (B).
    Fig 16: Identifying End Cover And Brush Holder

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22. Install the starter .