Starter disassembly sequence
1 - screw; 2 – traction relay solenoid; 3 - front cover; 4 - coupling screw; 5 - screw; 6 - back cover; 7 - brush holder; 8 - stator; 9 - rotor; 10 - front bearing; 11 - rear bearing; 12 - screw; 13 - cover; 14 - snap ring; 15 - washer; 16 - plate; 17 - screw; 18 - middle holder; 19 - spring support; 20 - spring; 21 - adjusting washers; 22 - gear; 23 - lever; 24 - snap ring; 25 - pressure ring; 26 - small gear; 27 - spring; 28 - small gear shaft
Attention! The assembly of the starter is carried out in the reverse order of disassembly.
Gear clearance adjustment
1. Disconnect the starter motor wire from the terminal «M».
2. Use additional wires to connect the battery terminals to the S and M terminals.
Warning! The next check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
3. Turn on the ignition, the starter gear will move forward. Move the gear back with your finger and check the gap between the gear and the stopper with a feeler gauge.
4. If the gap differs from the required one, adjust it by adding or removing spacers between the traction relay and the front cover. Gear clearance: 0.5–0.2 mm.
Check of the traction relay of a starter
Disconnect the starter motor wire from the terminal «M». The traction relay is in good condition if the plunger is retracted when the battery terminals are connected to the terminals «S» And «M». If the gear does not extend, replace the traction relay.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
Checking the holding winding of the traction relay
Disconnect the starter motor wire from the terminal «M». With additional wires, connect the battery terminals to the terminal «S» and the housing of the traction relay and manually pull out the gear to the stopper. If the gear remains in this position, then the holding winding of the traction relay is working.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
Checking the return of the traction relay plunger
Disconnect the starter motor wire from the terminal «M». With additional wires, connect the battery terminals to the terminal «M» and the traction relay housing, while the starter gear should move forward. After disconnecting the wires, the starter gear should quickly return to its original position.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
Performance tests (idling)
1. To carry out the idle test, assemble the circuit shown in the figure.
2. Set the rheostat motor to a position where the voltmeter will show a voltage of 11.5 V, while checking the current consumed by the starter and make sure that the starter shaft turns easily and smoothly. If the consumed current differs from the required one, use the table to determine and eliminate the cause of the malfunction.
sign | Possible reason |
High current draw with low starter speed | Dirty bearing |
Friction of the rotor winding on the pole | |
The rotor winding and excitation coil are closed to «mass» | |
Damaged rotor winding | |
High current consumption in the absence of rotation of the starter shaft | Closed to «mass» solenoid switch |
The rotor winding and excitation coil are closed to «mass» | |
Stuck bearing | |
No current drawn and starter shaft does not rotate | Rotor and excitation coil damage |
Broken brush or broken flexible brush guide | |
Broken contact between brush and commutator | |
Low current draw with low starter speed | Incorrect connection of the winding of the excitation coil |
High current consumption at high starter shaft speed | Short circuit in the exciter coil |