3-34 Engine Electrical Industrial 1.6L
Starter Motor Inspection
Cleaning Procedure
Notice: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the
grease packed in the clutch and damage the armature and the field coil insulation.
Clean all starter motor parts with a soft cloth prior to testing.
Inspection Procedure
Inspection in the following steps refers to visual inspection of the starter motor parts and assemblies in order to
determine the serviceability of the parts.
1. Inspect all parts for cracks, distortion, or other structural damage. Replace parts and assemblies that are
cracked, bent, or otherwise damaged.
2. Inspect the threaded parts for stripped, crossed, or otherwise damaged threads. Replace parts as necessary.
• Replace the parts with thread damage that cannot be cleaned up using a suitable tap or die.
• Replace any hardware items that have damaged threads.
3. Inspect the solenoid assembly for a cut or torn boot. If the boot is damaged, replace the solenoid assembly.
4. Inspect the clutch drive assembly. Replace the clutch drive assembly as necessary. Look for the following
damage:
• The pinion gear turns roughly or turns in both directions.
• The pinion gear teeth are broken or show evidence of step wear.
• The shift lever collar shows deep scoring or other damage.
Component Electrical Testing
Perform the following electrical tests in order to determine the serviceability of the starter assemblies.
1. Using an ohmmeter, check the windings of the solenoid assembly for continuity using the following procedure:
• Check the resistance of the solenoid pull–in and hold–in windings in a series by measuring the resis
tance between the motor terminal and the solenoid case.
• A resistance reading well above 1.95 ohms indicates a break or fault in the winding continuity.
• A resistance reading well below 1.95 ohms indicates a short or ground in the winding circuit.
• Replace the solenoid assembly if the resistance reading is extremely high or very low.
2. Check the armature for shorts, opens and grounds using the following procedure. Replace armature if it is
shorted, grounded, or has any evidence of an open circuit.
2.1. Rotate the armature in a growler.
2.2. Hold a steel strip such as a hacksaw against the armature.
2.3. If the steel strip vibrates in an area, a short is present.
− Using a self–powered test lamp or ohmmeter, check for continuity between the armature shaft and
any point on the commutator. Continuity indicates a ground.
− Inspect the points where the armature conductors join the commutator for signs of arcing or burning.
These signs indicate opens.
Armature Bearing Replacement
Notice: Ball bearings that are removed from the armature must be replaced with new bearings. The removal proce-
dure causes internal damage to the bearings.
Removal Procedure
Remove the commutator end or drive end bearings from the armature assembly using a suitable bearing puller.
Installation Procedure
1. Install the new commutator end and/or drive end bearings to the armature assembly using a tube that bears only
on the bearing inner race.
2. Press on the bearing until the inner race bottoms out against the shoulder of the armature shaft.
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