Starter repair

Starter details are shown in fig. 10.3. Before disassembling the starter, make sure it is defective by following these simple checks.





1. Using a screwdriver, check the ease of movement of the drive coupling along the shaft.



2. Rotate the drive gear. The gear should turn easily relative to the clutch hub in the direction of rotation of the armature and should not turn in the opposite direction.




3. Wire for «smoking» terminal «minus» the battery removed from the car with the starter housing. Connect the second wire at one end to the terminal «plus» battery, and the other - to the output of the control wire of the traction relay. If the traction relay is working properly, a click will be heard and the drive clutch will extend. Otherwise, the traction relay is faulty.



4. Disconnect the wire from the control output of the traction relay and connect it to the bottom contact bolt of the traction relay. The starter armature should begin to rotate at a frequency of more than 6000 min^-1. Otherwise, repair the starter.

You will need: keys «on 10», «at 13», socket wrench TORX T25, screwdrivers with flat and Phillips blades, pliers, hammer.




1. Unscrew the nut of the lower contact bolt of the traction relay..



2.... and disconnect the bus from the contact bolt of the traction relay.



3. Remove the three screws securing the traction relay to the starter cover from the drive side...



4.... and remove the traction relay by disconnecting the armature from the drive lever.




5. Remove the armature and return spring from the traction relay housing.



6. Turn out two screws of fastening of a cover of the bearing …



7.... remove the cover..



8.... and an o-ring.




9. Remove the circlip..



10.... and thrust washer.



11. Turn out two bolts of fastening of a cover from a collector..



12.... and remove the cover.



13. Remove the brush holder assembly with brush housings.



14. If necessary, remove the brush housings and springs.

15. Remove the cover from the drive side and remove the rotor from the starter housing.



16. Remove the rubber seal..



17.... and remove the drive assembly with the lever from the cover.



18. Remove the drive lever.



19. Slide the restrictive ring along the shaft of the planetary gearbox..



20.... and remove the retaining ring by prying it with a screwdriver.

21. Remove the restrictive ring..



22.... and drive from the planetary gear shaft.



23. Inspect the brush holder. Check the protrusion of the brushes in the brush holder. Use an ohmmeter to check the insulated housings for a short to ground. The resistance should tend to infinity.



24. The splines and trunnions of the armature shaft must not be damaged (nicks and burrs). The anchor collector must not show signs of burning. Eliminate minor burns with a rag soaked in gasoline and fine-grained sandpaper. Using an ohmmeter, check the armature winding for a short circuit. The resistance should tend to infinity.

25. Check whether the armature of the starter traction relay moves easily, whether the contact bolts are closed with a contact plate (using an ohmmeter).

26. Check drive. The drive gear teeth should not show significant wear. The gear should turn easily relative to the clutch hub in the direction of rotation of the armature and should not turn in the opposite direction. If the gear teeth are worn or damaged, or the gear turns in both directions, replace the drive.

27. There should be no cracks or signs of significant wear on the fork grooves on the starter drive lever.

Assemble the starter in the reverse order of disassembly, taking into account the following features.

1. Lubricate the splined surface of the armature shaft with silicon grease.

Attention! During operation, the drive clutch does not need to be lubricated. However, it must be cleaned of dirt. Do not use cleaners to clean the drive, which can wash out the lubricant embedded in its coupling.

2. Lubricate the bearings with engine oil (bushings) in the starter covers.



3. To install the restrictive ring, use the sliding pliers.



4. When installing the brush holder on the anchor, spread the brushes and fix with a mandrel (e.g. with a socket from the tool kit).

5. Apply a thin layer of silicone sealant to the surface of the relay that contacts the starter cover on the drive side before installing the traction relay.