Starter Motor, Disassemble, Inspect and Assemble - Repair

Starting motor and relay _ Repair
Mechanic Development Program
Starter motor, disassemble, inspect and

assemble
Incl. function check
Cau
tion
Follow the instructions carefully in order to avoid personal injury or damage to
products or equipment.
Part number: 1161033, 1161138, 1161246
Special tools: 9990148
Other special equipment: 9510060, 9988460
Disassembly
1
Place a plastic bag over the front bearing housing and the starter pinion and seal it.
Clean the outside of the starter motor before commencing.
Note: Cleaning agent must not be allowed to enter via the starter pinion, as this will
dissolve the lubricant in the overrunning clutch.
Grip the starter motor in a vice with soft jaws. Mark the position of the stator shell in
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relation to the front and rear bearing housings. Mark the control relay and the front
bearing housing.
3
Go directly to step 13 if the starter motor is not being disassembled completely and only
the brushes are to be inspected.
The starter pinion must be removed if the starter motor is being disassembled
completely.
Remove all the electrical connections on

the control relay. Remove both bolts holding the control relay to the front bearing
housing.

Lift up the control relay and pull it out.

Make sure the sealing ring comes with it.
Pull out the starter pinion and shaft. Place a counterhold 9990148 behind the fork arm.
Push in the washer and tension the fork arm with the wing nut.

Use a 19 mm socket to tap in the stop ring for the lock ring.
Note: The stop ring is then approx. 3.5 mm from the end of the shaft.
Remove the lock ring. Use a narrow screwdriver to prise out the lock ring.
10

Remove the stop ring, starter pinion and spring.
11
Remove the starter relay from the front bearing housing.
12
Unplug the electric connector. Remove the counterhold 9990148.
13
Grip the front bearing housing in a vice. Remove the two bolts for the brush retainer and
the long through bolts for the bearing housing.
14

Lift up the bearing housing.
15
Bend one end of a piece of piano wire

( 3 mm) 90 degrees.
Hook it onto the brush spring and pull out the spring, secure the brush with the spring.
Note: Do not pull out the spring any farther than the brush can just be pulled out.
Otherwise, there is a risk that the spring will break.
16

Pull out all the brushes from the brush retainer. Release the springs into the brush
retainer to relieve them.
17
Remove the O-ring located on one end of the stator shell. Lift up the seal for the thermal
protection.
18
Lift off the brush retainer.
19

Lift up the rotor and remove the ball if it is still on the rotor.
20
Lift off the stator and remove the O-ring on the end.
21

Remove the metal cover and seal.
22
Pull up the seal and washer for the fork arm.
23

Lift up the planetary gear with the overrunning clutch and fork arm. Remove the fork
arm.
Note: Make a note of the direction of the fork arm.
24
Pull apart the planetary gear including the shaft from the overrunning clutch.
Check and note the location of both E-circlips. Lay a cloth or piece of paper over the E-
circlips and remove them.
Cau
tion

The E-circlips can shoot off during removal.
Note: The raised part of the E-circlip must be facing the planetary gear.
25
Pull apart the clutch and the shaft as follows:

Press the planetary gear against the overrunning clutch. Hold the gear with one finger
and turn the shaft to change the position of the splines in the overrunning clutch.
Note: If the splines are in the wrong position, it will not be possible to pull apart the
clutch and the shaft.
26
Pull out the shaft from the planetary gear ring gear. Then remove the planet gear and

the wear washer from the bottom of the ring gear and the ball for the rotor shaft under
the needle bearing in the planetary gear if not removed earlier.
Clean and check

General
Change the rotor if it is worn or the test values are incorrect.
Check the gears, ball race and bearing with O-ring for wear.

Check for a ground fault in the windings with multimeter 9510060 or a so-called
Growler and a suitable piece of metal, e.g. a hacksaw blade. If the windings are short-
circuited, the piece of metal will make a fluttering sound when it is held over the rotor.
Other special equipment: 9510060
Measure the diameter of the commutator.

Min 38.1 mm.
Specifications:
38.1 mm
Measure the distance down to the commutator insulation and compare with the

diameter measured on the commutator.

Min depth 0.2 mm.
If the surface of the commutator is rough, burnt or oval, it can be machined down.
Note: Remove as little material as possible. The diameter of the commutator must not
be below 38.1 mm.
After machining down the commutator, cut the commutator insulation to a depth of
approx. 0.4 mm. Use a milling machine or specially ground hacksaw blade.
A = Incorrect machining
B = Correct machining
Field winding
General
Check the field winding cable for short circuit or open circuit. Use multimeter 9510060.
Change the stator shell if the test values are incorrect.
Check the ground:

Connect the multimeter to the field winding and the stator shell.
Turn the multimeter knob to buzzer mode. The buzzer should not sound at this
stage.
Check for open circuit:

Connect the multimeter to the field winding cable and the brush.
Turn the multimeter knob to buzzer mode. The buzzer should sound.
Brush retainer
General
Inspect the brush retainer for wear, short circuit and open circuit. Use multimeter
9510060.
Change the brush retainer and stator shell if the test values are incorrect.
1. Thermal protection

2. Insulation
3. Insulation
Measure the length of the brush, min 11.0 mm. If the brush is shorter than 11.0 mm,
change the brush retainer and stator shell.
Check that the brush does not stick in the retainer and that the springs are not fatigued
or cracked.
Specifications:
min 11.0 mm

Connect the multimeter to the metal on the brush retainer and to the cable for
the thermoswitch.
Turn the multimeter knob to buzzer mode. The buzzer should sound.
Check the ground:

Connect the multimeter to the metal on the brush retainer and to the brush
sleeve that is insulated to the brush retainer.
Turn the multimeter knob to buzzer mode. The buzzer should not sound.
Overrunning clutch, planetary gear

General
The overrunning clutch is filled with lubricating grease and must not be washed with
liquid.
Change the overrunning clutch together with the planetary gear if any of the
components are defective.
Grip the overrunning clutch shaft in a vice.
2
Rotate the shaft. It should rotate easily in one direction.
Note: It should not be possible to rotate the shaft in the opposite direction.
3
Inspect the splines on the shaft.

Check the planetary gear for wear on the gears, ring gear, needle bearing and journals.
Check also the bearing in the ring gear.
In case of any defects, the whole planetary gear with overrunning clutch must be
changed.
Starter pinion
1
Check the starter pinion for wear, cracks and other damage. In case of any defects,
change the starter pinion.
Front bearing housing

1
Check the seal and bearing condition. Change the bearing housing if it is defective.
Fork arm
1
Check the fork arm for cracks and other defects.
Measure the fork arm pins, min 6.0 mm.
Specifications:
min 6.0 mm
Control relay
General
Inspect the control relay for short circuit and open circuit. Use multimeter 9510060.
Change the control relay if the values are incorrect.
A = Starter key
B = Thermal protection

Connect the multimeter across connections M and S.

Set the multimeter knob to buzzer mode. The buzzer should sound.
Check the resistance of the H-coil ():

Connect across S and ground.
Value 1.2 -1.4 at +20C.
Check the resistance of the P-coil ():

Connect across M and ground.
Value 1.3 -1.6 at +20C
Connect across M and B.

Turn the multimeter knob to buzzer mode. The buzzer should not sound, i.e.
there should not be any contact between these points.
Then press the control piston all the way down. The buzzer should sound, i.e.
full contact should be obtained.
Starter relay
General
Inspect the starter relay for short circuit and open circuit. Use multimeter 9510060.
Change the starter relay if the values are incorrect.
Connect across SW and ground.

Check the resistance ():

Connect between SW and L.
Value 10.32 10% at +20C.

Specifications:
10.32 10%
Connect across SW and B

Connect the multimeter across connections B and S.

Assembly
1
Fill the space between the teeth on the ring gear with synthetic grease part no.:
1161033.
Part number: 1161033
2
Apply synthetic grease part no.: 1161033 on both sides of the wear washer and on the
bearing surface in the ring gear.
3
Place the wear washer and planet gear shaft into the ring gear.
4
Apply grease part no.: 1161138 to the splines on the planet gear shaft and the splines
in the overrunning clutch.
Assemble both shafts. Turn the shaft so that the splines are in such a position that they
cannot be separated.
Press down both E-circlips with the stamped boss facing the planetary gear.
Note: Make sure the stamped bosses on the E-circlips fit into each other and are facing
the planetary gear.

6
Coat the journals and needle bearing in the shaft as well as the gears with synthetic
grease part no.: 1161033.
7
Fit the gears to the journals.
8
Coat the overrunning clutch shaft with grease part no.: 1161246.
9
Apply a thin layer of grease (part no.: 1161246) to the surfaces in the ball bearing and
on the sealing ring in the front bearing housing as well as the surfaces on the fork arm
for the overrunning clutch.
10
Grip the front bearing housing in a vice.
11
Assemble the fork arm as marked.
Note: Movement will be limited if the plastic yoke on the fork arm is mounted in the
wrong direction.
12
Coat the fork arm pins and control relay mounting with grease part no.: 1161246.
13
Place the fork into the overrunning clutch and drop it into the bearing housing.
Position the ring gear lugs in the bearing housing.
14
Fit the washer for the fork arm plastic yoke. The flat side should be facing the planetary
gear.
Press down the seal.
15

Coat the side of the metal cover towards the planetary gear with synthetic grease part
no.: 1161033.
Fit the seal and the metal cover.
16
Coat the rotor gear teeth and the ball seat in the end of the shaft with synthetic grease
part no.: 1161033.
17
Fit the ball into the end of the shaft and drop the rotor into the planetary gear.
Note: Make sure the ball does not fall out.
18
Place a new O-ring in the groove on the end of the stator.
Place the stator over the rotor as marked.
19
Pull out the brush spring in the brush retainer and secure both the brush and the
springs.
Place the brush retainer and a new O-ring in the groove on the end of the stator.
20
Pull out the brush springs and push all the brushes into the retainer.
Note: Do not pull out the spring any farther than the brush can just be fitted.
Note: Make sure the cables on the brush are outside the outer diameter of the brush
retainer.
21
Cut off the head of an M5x30 mm bolt and screw it into one of the threaded brush
retainer holes as a guide.
Coat the bearing seat in the rear cover with grease part no.: 1161246.
Lubricate the threads on both the long through bolts.
22
Fit the O-ring on the bearing if it was removed.
23

Fit the bearing housing as marked and tighten the screws to 10.2 2.4 Nm.
Specifications:
10.2 2.4 Nm
24
Screw in one of the bolts for the brush holder through the bearing housing.
Remove the guide bolt and fit the other bolt. Tighten the bolts to 3.4 1.0 Nm.
Specifications:
3.4 1.0 Nm
25
Fit counterhold 9990148 under the fork arm. Tighten with the wing nut.
26
Fasten the starter motor to the stator. Fit the spring, starter pinion and a new stop ring.
27
Fit a new lock ring on the shaft. Press out the stop ring with a screwdriver and press the
lock ring into the stop ring groove.
Note: Make sure the stop ring is located approx. 1.5-2.0 mm under the end of the shaft.
The stop ring should be easy to turn.
28
Remove the counterhold tool.
29
Fit the seal in the end of the control relay if it was removed.
Lubricate the fork arm groove on the control relay with grease part no.: 1161246.
Fit the control relay as marked and hook it onto the fork arm.
Apply locking fluid part no.: 1161053 to the bolts holding the control relay to the front
bearing housing. Fit and tighten the bolts to 6.8 1.9 Nm.
Part number: 1161246 1161053

Specifications:
6.8 1.9 Nm
30
Screw on the starter relay. Tighten the bolts to 6.8 1.9 Nm.
Specifications:
6.8 1.9 Nm
31

Plug in the thermal protection connector to the control relay. Connect all cables to the
control relay. Tighten the nut (M10) for the cable between the stator and the control
relay to 18 2 Nm.
Tighten the bolt (M5) on the control relay to 3.4 1 Nm.
Specifications:
18 2 Nm 3.4 1 Nm
Function check
Test of starter motor without load
Wiring diagram
1. Ammeter
2. Battery (24V)
3. Voltmeter
4. Starter key
5. Starter motor
1
Connect the starter motor according to the wiring diagram.
Note: Use cables 35 - 50 mm for the power supply to the control relay. 2.5 mm for
other cables.
Tighten all connections.
2
Apply current to the starter relay and check the speed with a tachometer 9988460 and
the current (A) and voltage (V). Compare test values with the specifications. Starter
motor.
Warning
Cut the current within 10 sec. Continued current supply can cause overheating and
damage the starter motor.Other special equipment: 9988460
3
Repeat the test after about 1 min.
4
Perform a new check of the starter motor components if incorrect values are obtained.

Starter Motor, Disassemble, Inspect and Assemble - Repair

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Starter Motor, Disassemble, Inspect and Assemble - Repair

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Starting motor and relay _ Repair

Mechanic Development Program

Starter motor, disassemble, inspect and

Part number: 1161033, 1161138, 1161246

Special tools: 9990148

Other special equipment: 9510060, 9988460

Create by Plant Instructor Pasar panas 159_Print date 07/04/2017 1/22

Remove all the electrical connections on

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Lift up the control relay and pull it out.

Special tools: 9990148

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Remove the stop ring, starter pinion and spring.

Special tools: 9990148

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Lift up the bearing housing.

Bend one end of a piece of piano wire

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Lift off the brush retainer.

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Remove the metal cover and seal.

Pull up the seal and washer for the fork arm.

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Note: Make a note of the direction of the fork arm.

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The E-circlips can shoot off during removal.

Pull apart the clutch and the shaft as follows:

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Clean and check

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Other special equipment: 9510060

Measure the diameter of the commutator.

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diameter measured on the commutator.

Check the ground:

Check for open circuit:

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Check for open circuit:

Check the ground:

Overrunning clutch, planetary gear

Grip the overrunning clutch shaft in a vice.

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Front bearing housing

Measure the fork arm pins, min 6.0 mm.

Check for open circuit:

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Connect the multimeter across connections M and S.

Check the resistance of the H-coil ():

Check the resistance of the P-coil ():

Connect across M and B.

Connect across SW and ground.

Check the resistance ():

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Connect across SW and B

Connect the multimeter across connections B and S.

Part number: 1161033

Part number: 1161033

Part number: 1161138

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Part number: 1161033