58
INSPECTION AND REPAIR
1.
The pinion gear parts should be checked for damage
or wear. If the gear does not engage or slips, it should
be washed in solvent ( rubber parts cleaned in soap
and water) to remove dirt and grease, and dried before
reassembly. Also check the armature and drive nut
splines for wear or damage. Replace parts as
necessary.
2.
The brushes and brush card holder should be checked
for wear. With the armature in place and the brushes
engaging the commutator surface, check the brushes
for wear. Brushes should be replaced if the brush wire
approaches the bottom of the brush holder slot. Brush
springs must exhibit enough strength to keep tension
on the brushes and hold them on the commutator.
3.
The field windings can be checked using a continuity
light or ohmmeter. Attach one lead to each field coil
connection. Continuity should exist between each field
coil connection, and no continuity should exist between
the field coil connections and the starter housing (diag.
36 & 37).
4.
The armature should be checked for glazing or wear. If
necessary the armature can be turned down in a lathe.
While rotating, polish the commutator bars using a
piece of 00 sandpaper (diag. 38). Light pressure and
back and forth movement should be used. Recut the
commutator bars to a depth equal to the width of the
insulators between the bars. Check for continuity
between the copper commutator bars and the iron of
the armature, none should exist (diag. 39). If any is
noted the armature must be replaced.
38
39
Brush Card Replacement
1.
Loosen but do not remove the two nuts on the starter terminal post.
2.
Remove the nuts holding the end cap in place. Remove the end cap and the thrust washer.
3.
Grasp the thru bolts using a vise grip positioned as close to the flanged end as possible to prevent thread damage.
Remove the two nuts holding the driving end cap in place. Remove the armature and driving cap assembly, followed
by the two thru bolts. Notice the position of the brush ground eyelet under the thru bolt flange.
4.
Note or mark the position of the connectors of the brush wires. Use a wire cutter to clip the solid field wires as close
to the connectors as possible.
5.
Note or mark the brush card in the starter housing and remove the brush card assembly. Clean the accumulated dirt
off all starter parts. Scrape the insulating varnish off the last 1/2" (12.7 mm) of the solid field wires.
6.
Insert the new brush card into position while guiding the solid field wires through the proper slots in the brush card.
7.
Crimp and solder the brush leads to the solid field wires. Use a needle nose pliers or vise grip to hold the woven brush
lead close to the connector while soldering. This prevents solder and heat from flowing up the brush lead. Insulate the
crimped connection nearest the starter terminal post using electrical tape or heat shrink tubing. Route the wires to
prevent damage during assembly.
8.
Install the armature into the housing while spreading the brushes. Install the thru bolts while checking to make sure
the bolts go thru the ground brush eyelet terminals. Install and tighten the drive end thru bolt nuts, but do not
overtighten.
9.
Install the thrust washer (cupped side faces towards the end cap) on the end of the armature and then install the
starter end cap. Secure the cap with the locking nuts and tighten the nut on the starter terminal post. Rotate the
armature by hand to check for binding before installation on the engine.
12 VOLT
120 VOLT
CONNECTION POINT OF
POWER CORD LEADS
37
36
FIELD COIL
CONNECTORS
FIELD COIL
CONNECTORS
BRUSH
SPRINGS
