2.
When replacing field coil brushes, crush worn out brush with pliers, taking care not to damage pigtail.
Disconnect the battery ground cable.
Remove the speedometer cable and the shift cable.
Disconnect the starter motor connector and terminal.
Remove the starter motor assembly.
Installation is the reverse order of removal.
Brushes that are worn out, or oil-soaked, should be replaced.
When replacing field coil brushes, crush worn out brush with pliers, taking care not to damage pigtail.
Sand the pigtail end with sandpaper to ensure good soldering.
Insert the pigtail into hole provided in the new brush and solder it. Make sure that the pigtail and excess solder do not come out onto the brush surface.
When replacing the ground brush, slide the brush from brush holder by prying retaining the spring back.
Place the armature on a pair of V-blocks, and check the deflection by using a dial gauge.
Standard value
Armature run-out : 0.05 mm (0.002 in.)
Limit
Armature run-out : 0.1 mm (0.0039 in.)
Check the outer diameter of the commutator.
Standard value
Outer diameter of the commutator : 29.4 mm (1.157 in.)
Limit
Outer diameter of the commutator : 28.4 mm (1.118 in.)
Check the depth of the undercut between segments.
Standard value
Depth of the undercut between segments :
0.5 mm (0.020 in.)
Limit
Depth of the undercut between segments :
0.2 mm (0.079 in.)
Make sure there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity, replace the brush holder assembly.
While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should not rotate in opposite direction. If clutch does not function properly, replace the overrunning clutch assembly.
Inspect pinion for wear or burrs. If pinion is worn or burred, replace overrunning clutch assembly. If pinion is damaged, also inspect ring gear for wear or burrs.
Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only.
Do not immerse drive unit in cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch.
The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
