Page 1625 of 2890

G6M0038
2) Run-out test
Check the commutator run-out and replace if it exceeds the
limit.
Commutator run-out:
Standard
0.02 mm (0.0008 in), or less
Service limit
Less than 0.05 mm (0.0020 in)
G6M0039
3) Depth of segment mold
Check the depth of segment mold.
Depth of segment mold:
0.6 mm (0.024 in)
Limit
0.2 mm (0.008 in)
G6M0040
4) Armature short-circuit test
Check armature for short-circuit by placing it on growler
tester. Hold a hacksaw blade against armature core while
slowly rotating armature. A short-circuited armature will
cause the blade to vibrate and to be attracted to core. If the
hacksaw blade is attracted or vibrates, the armature, which
is short-circuited, must be replaced or repaired.
G6M0041
5) Armature ground test
Using circuit tester, touch one probe to the commutator
segment and the other to shaft. There should be no conti-
nuity. If there is a continuity, armature is grounded.
Replace armature if it is grounded.
B6M0435
2. YOKE
Make sure pole is set in position.
12
6-1SERVICE PROCEDURE
1. Starter
Page 1626 of 2890

B6M0436
3. OVERRUNNING CLUTCH
Inspect teeth of pinion for wear and damage. Replace if it
is damaged. Rotate pinion in direction of rotation (clock-
wise). It should rotate smoothly. But in opposite direction,
it should be locked.
CAUTION:
Do not clean overrunning clutch with oil to prevent
grease from flowing out.
B6M0437
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length and replace if it exceeds the
service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard 15 mm (0.59 in)
Service limit 10 mm (0.39 in)
2) Brush movement
Be sure brush moves smoothly inside brush holder.
B6M0438
3) Insulation resistance of brush holder
Be sure there is no continuity between brush holder and its
plate.
4) Brush spring force
Measure brush spring force with a spring scale. If it is less
than the service limit, replace brush spring.
Brush spring force:
Standard
18.6 N (1.9 kg, 4.2 lb) (when new)
Service limit
6.9 N (0.7 kg, 1.5 lb)
13
6-1SERVICE PROCEDURE
1. Starter
Page 1627 of 2890
B6M0439A
5. BEARING
1) Rotate bearing by hand; no binding should exist.
2) Rotate bearing rapidly; no abnormal noise should be
heard.
E: ASSEMBLY
Assembly is in the reverse order of disassembly proce-
dures. Observe the following:
1) Before assembling, lubricate disassembled parts at the
points shown in“COMPONENT PARTS 6-1 [C101] and 6-1
[C102]”.
Grease:
ESSO BEACON 325
SCHELL ALVANIA GREASE RA or equivalent
B6M0470A
2) Assembling magnetic switch, clutch, and housing
To assemble, first install clutch to magnetic switch, then
install idle gear, and finally install clutch.
CAUTION:
Do not forget to install steel ball and coil spring to
clutch.
Attach bearing to idle gear beforehand.
B6M0427A
3) Installing armature to yoke
CAUTION:
Do not forget to put felt washer on armature shaft bear-
ing.
B6M0471A
4) Installing brushes
Assemble brush holder to yoke as shown, then assemble
two yoke-side brushes to brush holder.
14
6-1SERVICE PROCEDURE
1. Starter
Page 1628 of 2890
B6M0472A
5) Installing end frame
When assembling end frame to yoke, align notched portion
of end frame with lead wire grommet.
B6M0473A
6) Installing yoke
When installing yoke to magnetic switch, align notch of
yoke with protrusion of magnetic switch.
G6M0095
2. Generator
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0088
2) Disconnect connector and terminal from generator.
G2M0286
3) Remove V-belt cover.
4) Remove front side V-belt.
15
6-1SERVICE PROCEDURE
1. Starter - 2. Generator
Page 1629 of 2890
B6M0472A
5) Installing end frame
When assembling end frame to yoke, align notched portion
of end frame with lead wire grommet.
B6M0473A
6) Installing yoke
When installing yoke to magnetic switch, align notch of
yoke with protrusion of magnetic switch.
G6M0095
2. Generator
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0088
2) Disconnect connector and terminal from generator.
G2M0286
3) Remove V-belt cover.
4) Remove front side V-belt.
15
6-1SERVICE PROCEDURE
1. Starter - 2. Generator
Page 1630 of 2890
G2M0090
5) Remove bolts which install generator onto bracket.
G2M0090
6) Installation is in the reverse order of removal.
CAUTION:
Check and adjust V-belt tension.
B6M0476A
B: DISASSEMBLY
1) Heat the portionAof rear cover to 50°C (122°F) with
heater drier.
G6M0065
2) Remove the four through bolts. Then insert the tip of a
flat-head screwdriver into the gap between the stator core
and front bracket. Pry then apart to disassemble.
G6M0066
3) Hold rotor with a vise and remove pulley nut.
16
6-1SERVICE PROCEDURE
2. Generator
Page 1631 of 2890
B6M0477A
CAUTION:
When holding rotor with vise, insert aluminum plates
or wood pieces on the contact surfaces of the vise to
prevent rotor from damage.
B6M0478A
4) Remove rotor from front cover.
5) Remove three screws from front cover and then bear-
ing retainer and ball bearing.
B6M0479A
6) Remove bolt which secure battery terminal bolt, and
remove rear cover. Remove nuts which secure diode plate,
and remove stator and rear cover.
B6M0480A
7) Separate diode plate from stator coil.
(1) Cut the connecting position
Aof stator coil to
diode.
(2) Unsolder connection
Band throughout the lead
wire of stator coil.
B6M0481
(3) Remove stator coil from diode plate.
17
6-1SERVICE PROCEDURE
2. Generator
Page 1632 of 2890
B6M0482
8) Remove bolts which secure IC regulator, diode and
brush holder.
CAUTION:
Do not apply a shock or load to IC regulator cooling
fins.
G6M0075
C: INSPECTION AND REPAIR
1. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of the
sliding surface.
Clean or polish with #500 to #600 emery paper if defective.
B6M0483A
2) Slip ring outside diameter
Measure slip ring outside diameter. If slip ring is worn,
replace rotor.
Slip ring outside diameter:
Standard
27 mm (1.06 in)
Limit
26 mm (1.02 in)
B6M0484A
3) Continuity test
Check continuity between slip rings. If continuity does not
exist, replace rotor.
B6M0485A
4) Insulation test
Check continuity between slip ring and rotor core or shaft.
If continuity exists, replace rotor.
18
6-1SERVICE PROCEDURE
2. Generator