ELECTRIC STARTER

Removing the starter motor

Order

Job/Parts to remove

Q’ty

Remarks

 

Exhaust pipe

 

Refer to ENGINE REMOVAL.

1

Starter motor lead

1

 

2

Starter motor

1

 

Disassembling the starter motor

Order

Job/Parts to remove

Q’ty

Remarks

1

Starter motor assembly

1

 

2

O-ring

1

 

3

Starter motor front cover

1

 

4

Washer

1

Starter motor front cover

5

Starter motor yoke

1

 

6

Gasket

2

 

7

Armature assembly

1

 

8

Washer

1

 

9

Circlip

1

 

10

Starter motor rear cover

1

 

11

Brush set

1

 

CHECKING THE STARTER MOTOR

1.Check:

  • Commutator

    Dirt → Clean with 600 grit sandpaper.

2.Measure:

  • Mica undercut “a”

    Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.

  • Mica undercut (depth)

    1.50 mm (0.06 in)

The mica of the commutator must be undercut to ensure proper operation of the commutator.

3.Check:

  • Armature assembly

a.Connect the digital circuit tester to the armature coil and check the continuity.

  • Digital circuit tester (CD732)

    90890-03243

  • Model 88 Multimeter with tachometer

    YU-A1927

b.If there is no continuity, replace the starter motor.

4.Measure:

  • Brush length “a”

    Out of specification → Replace the brush set.

  • Brush overall length limit

    3.5 mm (0.14 in)

5.Measure:

  • Brush spring force

    Out of specification → Replace the brush set.

  • Brush spring force

    3.92–5.88 N (400–600 gf, 14.11–21.17 oz)

6.Check:

  • Gear teeth

    Damage/wear → Replace the starter motor.

7.Check:

  • Oil seal

    Damage/wear → Replace the defective part(s).

ASSEMBLING THE STARTER MOTOR

1.Install:

  • Brush spring “1”

  • Brush “2”

Align the corner of brush terminal “a” with groove “b” and fit them together.

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 starter motor rear cover.

  • Align the match mark “b” on the starter motor yoke with the match mark “c” on the starter motor rear cover.

4.Install:

  • Circlip “1”

  • Plain washer “2”

  • Gasket “3”

  • Washer (starter motor front cover) “4”

  • Starter motor front cover “5”

  • For installation, align the projections on the washer with the slots in the front cover.

  • Align the match mark “a” on the starter motor yoke with the match mark “b” on the starter motor front cover.

5.Install:

  • Bolt “1”

  • O-ring “2”

Apply the lithium-soap-based grease on the O-ring.

6.Install:

  • Starter motor

  • Starter motor bolt

  • Starter motor bolt

    10 N·m (1.0 kgf·m, 7.4 lb·ft)