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7-11
ELECTRIC STARTING SYSTEM
CHECKING AND REPAIRING THE
STARTER MOTOR
1. Check:
Commutator
Dirt Clean with 600 grit sandpa-
per.
2. Measure:
Commutator diameter "a"
Out of specificationReplace the
starter motor.
3. Measure:
Mica undercut "a"
Out of specification Scrape the
mica to the proper measurement
with a hacksaw blade which has
been grounded to fit the commu-
tator.
The mica must be undercut to ensure
proper operation of the commutator.
4. Measure:
Armature assembly resistances
(commutator and insulation)
Out of specificationReplace the
starter motor.
a. Measure the armature assembly
resistances with the pocket tester.
b. If any resistance is out of specifi-
cation, replace the starter motor.
5. Measure:
Brush length "a"
Out of specificationReplace the
brushes as a set.
6. Measure:
Brush spring force
Out of specificationReplace the
brush springs as a set.
ASSEMBLING THE STARTER
MOTOR
1. Install:
Brush spring "1"
Brush "2"
2. Install:
Armature assembly "1"
Install while holding down the
brush using a thin screw driver.
Be careful not to damage the brush
during installation.
3. Install:
Gasket "1"
Starter motor yoke "2"
Install the starter motor yoke with its
groove "a" facing front cover.
Align the match mark "b" on the
starter motor yoke with the match
mark "c" on the starter motor rear
cover.
4. Install:
Gasket "1"
Circlip
Plain washer "2"
Washer (starter motor front cover)
"3"
Starter motor front cover "4"
Min. commutator diame-
ter:
16.6 mm (0.65 in)
Mica undercut:
1.5 mm (0.06 in)
Pocket tester:
YU-3112-C/90890-
03112
Armature assembly:
Commutator resis-
tance "1":
0.0189–0.0231 Ω at 20
°C (68 °F)
Insulation resistance
"2":
Above 1 MΩat 20 °C
(68 °F)
Min. brush length:
3.5 mm (0.14 in)
Brush spring force:
3.92–5.88 N (400–600
gf, 14.1–21.2 oz)
220


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