1. Use a screwdriver to check that the drive freewheel can move freely along the shaft.
2. Rotate the drive gear. It should rotate easily relative to the coupling hub in the direction of rotation of the armature and should not rotate 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 second - 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 must be replaced.
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 speed of more than 6000 rpm. Otherwise, repair the starter.
You will need: key «for 8», end head «at 13», Phillips screwdriver, sliding pliers.
1. Unscrew the nut on 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.
5. Turn out two bolts of fastening of a cover from the drive...
6.... separate the starter cover and housing and remove the lever support along with the rubber spacer...
7.... and the drive lever.
8. Remove the drive side cover.
9. Turn out two screws of fastening of a cover from a collector...
10.... and remove the cover.
11. Remove the armature assembly with the brush holder from the stator.
12. Remove the brush holder from the armature.
13. Slide the stop ring over the armature shaft using a suitable drift.
14. Prying with a screwdriver, remove the retaining ring.
15. Remove the restrictive ring from the armature shaft...
16.... and drive.
17. Inspect the brush holder. Check the height of the brushes in the brush holder. If the height is 7 mm or less, replace the brush holder with a new one. Use an ohmmeter to check the insulated holders for a short to the housing. The resistance should tend to infinity.
18. 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 emery cloth. Check the armature winding for a short circuit with an ohmmeter. The resistance should tend to infinity.
19. Check whether the armature of the starter traction relay moves easily, whether the contact bolts are closed with a contact plate (using an ohmmeter).
20. Check drive. The drive gear teeth must 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.
21. 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 General Electric CG321 silicone grease or equivalent.
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. 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.
5. Before installing the brush holder on the anchor, spread the brushes and fix in any way possible (e.g. with a suitable mandrel).