Page 2313 of 2389
4. REMOVE BRUSH HOLDER
(a) (1.0 kW Type)
Remove the two screws and end cover from the field
frame.
(1.4 kW Type)
Remove the two screws, 0±rings and end cover from the
field frame.
(b) (1.4 kW Type)
Remove the 0±ring. (b) Remove the following parts from the magnetic switch:
(1.0 kW Type)
(1) Starter housing and clutch assembly
(2) Return spring
(3) Bearing
(4) Idler gear
(c) Using a screwdriver, hold the spring back and disconnect the
brush from the brush holder. Disconnect the four brushes,
and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME(1.4 kW Type)
(1) Starter housing and clutch assembly
(2) Return spring
(3) Pinion gear
(4) Bearing
(5) Idler gear
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the
clutch shaft hole.
± STARTING SYSTEMStarterST±5
Page 2314 of 2389
INSPECTION AND REPAIR OF STARTER
Armature Coil
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator
If there is no continuity, replace the armature.
2. INSPECT COMMUTATOR FOR RUNOUT
(a) Place the communicator on V±blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it with
on a lathe.
Commutator
1. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct with sandpaper
(No.400) or on a lathe.2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR DIAMETER
Using calipers, measure the diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter 29.0 mm (1.142 in.)
± STARTING SYSTEMStarterST±6
Page 2315 of 2389

Brushes
INSPECT BRUSH LENGTH
Using calipers, measure the brush length.
Standard length:
1.0 kW type 13.5 mm (0.531 in.)
1. 4 kW type 15.5 mm (0±610in.)
Minimum length:
1.0 kW type 8.5 mm (0.335 in.)
1.4 kW type 10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder
and field frame.
Brush Springs
INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sep-
arates from the brush.
Standard installed load:
1.79±2.41.kg (3.9±5.31b, 18±24N)
If the installed load is not as specified, replace the brush
springs.4. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign
material. Smooth out the edge.
Standard undercut depth: 0.6 mm 10.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with
hacksaw blade.
Field Coil (Field Frame)
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, replace the field frame.
2. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity)
between the field coil end and field frame.
If there is continuity, replace the field frame.
± STARTING SYSTEMStarterST±7
Page 2316 of 2389

Clutch and Gears
1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and the
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel ring gear for wear or
damage.
2. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear counterclockwise and check that it
turns freely. Try to rotate the pinion gear clockwise and
check that it locks.
If necessary, replace the clutch assembly.
Brush Holder
INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (±) brush holders.
If there is continuity, repair or replace the brush holder.
3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY
A. Disassembly starter housing and clutch assembly
(a) Mount a brass bar in a vise, and install the starter housing
and clutch assembly to the brass bar.
(b) Push down the±pinion gear.
(c) Using a plastic±faced hammer, tap in the stop collar.
± STARTING SYSTEMStarterST±8
Page 2317 of 2389
B. Assemble starter housing and clutch assem-
bly
(a) Assembly the following parts:
(1) Starter housing
(2) Bearing retainer
(3) Starter clutch
(4) Compression spring
(5) Clutch shaft (g) Disassemble the following parts:
(1) Starter housing
(2) Bearing retainer.
(3) Starter clutch
(4) Compression spring
(5) Clutch shaft (e) Remove the following parts:
(1) Stop collar
(2) Pinion gear
(3) Compression spring
(f) Push down the starter housing, remove the spring re-
tainer. (d) Using a screwdriver, pry out the snap ring.
± STARTING SYSTEMStarterST±9
Page 2318 of 2389
(c) Push down the starter housing, and install the following
parts:
(1) Spring retainer
(2) Compression spring
(3) Pinion gear
(4) Stop collar
(h) Remove the starter housing and clutch assembly from
the brass bar.
(i) Using a plastic±faced hammer, tap the clutch shaft and
install the stop collar onto the snap ring. (d) Push down the pinion gear.
(e) Using snap ring pliers, install a new snap ring. (b) Mount a brass bar in a vise, install the starter housing
and clutch assembly to the brass bar.
(f) Using pliers, compress the snap ring.
(g) Check that the snap ring fits correctly.
± STARTING SYSTEMStarterST±10
Page 2319 of 2389
Bearings
1. INSPECT BEARINGS
Turn each bearing by hand while applying inward force.
If resistance is felt or if the bearing sticks, replace the
bearing.
Magnetic Switch
1. PERFORM PULL±11V 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.
2. PERFORM HOLD±IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between
terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch. (b) Using SST and a press, press in a new front bearing.
SST 1.0 kW Type 09285±76010
1.4 kW Type 09201±41020
(c) Using a press, press in a new rear bearing. 2. IF NECESSARY, REPLACE BEARINGS
(a) Using SST, remove the bearing.
SST 09286±46011
± STARTING SYSTEMStarterST±11
Page 2320 of 2389
ASSEMBLY OF STARTER
(See page ST±3)
HINT: Use high±temperature grease to lubricate the bearings
and gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME
Apply grease to the armature bearings, and insert the arma-
ture into the field frame.
2. INSTALL BRUSH HOLDER
(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush spring back, and
connect the brush into the brush holder. Connect the
four brushes.
HINT: Check that positive H lead wires are not grounded.
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
(a) Apply grease to the steel ball.
(b) Insert the steel ball into the clutch shaft hole. (d) 0 .4 kW Type)
Install a new O±ring to the end cover screw.
(e) Install the end cover with the two screws. (c) (1.4 kW Type)
Place a new O±ring in position on the field frame.
± STARTING SYSTEMStarterST±12