AK202802
CHARGING SYSTEM
ENGINE ELECTRICAL16-18
2.Check t he co ndition of the (−) heat sink by
checkin
g
con
t
inuity b
e
tween th e (
−) he at sink and
ea
ch o
f
the st
a
t
or co
il lead conne
cting termina l s.
If con t inu i ty is p r ese n t in bot h d i re ctio ns, the dio de
is shorted.
Re place the rectifier assembly .
AK202804
3.Check t he co ndition of the diode t r io by testing
continuity of ea ch o f the th ree diodes using a
circuit tester con necte d to both sides of the dio de.
Co nnect in a p o la rity a nd then reverse the polarity
fo r each test.
If continuity exist s or no cont inuity exist s for bo th
po
larities, the d i ode is d e fective . Repla c e th e
rectifier assembly if a
n y o f the d i odes is defe c tive.
BRUSH
AK202808
Protrusion
length
AB
1.Measure the lengt h of the prot rusion o f the bru s h.
Replace the b r ush if the protrusion lengt h is
shorter than th e limit .
Limit: 2 mm mini mum
2.Unsolde r the lead o f the br ush. The bru s h will
come out, b e coming ready for removal.
AK202834
Solder
AB
3.I n st all a ne w b r ush b y pu sh in g it int o the h o lde r a s
shown in the d r awing a nd soldering th e lea d .
STARTING SYSTEM
ENGINE ELECTRICAL16-27
<> SNAP RING/STOP RING REMOVAL
AK100883AC
Socket wrench
Stop ring Pinion Gear
Overrunning
clutch
1. Ap ply a lo ng socket wr ench o f a n ap pro p ria t e size
to the stop ring and strike th e wrench to drive out
th e sto p ring toward th e pin i on g ear side.
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
2. Remove the snap ring with sna p ring pliers, th en
remove the stop ring an d overrunning clutch.
STARTER MOT O R P ARTS CLEANING
Never clean in a solvent such st arte r moto r p a rt s as
th e ma gnetic switch, brush hold e r , and arma ture.
If they are soake d in a solven t, their insulat i on
could be imp a ire d . When these p a rt s requ ire
clean ing, wipe of f co nt a m in ation with cloth .
1.Never so ak th e drive un it in a solve n t. If it is
washed in a solvent, th e grea se ha vin g been
p a cke d in th e over run n ing clutch at t he fa ct or y will
be washe d out. Wipe t he drive u n it with cloth if it
req u ires cleaning.
REASSEM BL Y SER V ICE POINT S
>>A<< STOP RING/SNAP RING INST AL-
LATION
AK202911
Overrunning
clutch Stop ring
Snap ring
Stop ring
AB
Use a suit
able puller to pull the stop ring u n til it ge t s
over t
he snap ring.
INSPECTION
M1162 0013 0015 7
COMM.U.T .A T O R
AK202712
1.Sup port the arma ture with a p a ir o f V block a nd
tu rn it t o mea s ure the run out of the surface not
ru bbed b y the brushes u s in g a dial g auge.
St andard va lue: 0.0 5 mm o r l ess
Limit: 0.1 mm
AK202715
2.Measure the diameter o f the commut ator .
St andard va lue: 29 .4 mm
Limit: 28.8 mm
