Starting System

OUTLINE 2. When the starter switch is closed, current flows to the

STARTER MOTOR starter relay and "B"(battery terminal) and "S"(switch
terminal) of the starter relay are connected and
The starter motor is the system which converts electrical
current begins to flow to the starter plunger.
energy of battery into mechanical rotation energy to
supply more than minimum rpm of crankshaft required by
the starting of the internal combustion engine. Classifying
the starter motor, it is composed of such parts as
electrical motor part which turning force occurs, drive
part which transmits power to the ring gear, the magnetic
switch part which moves the pinion into the ring gear and
sends current to electrical motor.

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3. If current flows to the starter plunger, not only the

plunger but also the lever is pulled. Therefore, the
pinion moves to the ring gear side. As "B"(battery
terminal) and "M"(motor terminal) of magnet meet
from the specific engaged distance, large current
flows to the starter motor and the pinion rotates the
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OPERATION
1. When all circuits are connected, the pinion is not in
mesh with the ring gear if stater switch is opened.

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Starter motor
COMPONENTS

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DISASSEMBLY 4. Remove the rear bracket.
1. Disconnect each nut from the magnet switch
assembly.

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5. Remove the yoke assembly, the brush holder

SDFEE7039D assembly and the armature.
2. Remove the screw from the rear bracket.

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SDFEE7040D 6. Remove the mounting screw of the starter motor

3. Remove the through bolt from the rear bracket. relay.

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7. Remove the mounting screw of the magnet switch. 10.Remove the ball, the small gear and the shield.

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8. Remove the magnet switch (A). 11.Remove the hog-ring with an awl.

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9. Remove the plug using a long nose plier. 12.Remove the pinion, the spring and the retainer.

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13.Remove the shaft assembly and the lever. 16.While the holding (A), turn 1/2 pitch of (B) to
separate.

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14.Remove the lever pin.

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ASSEMBLY
Assembly is in the reverse order of disassembly.

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15.Remove the C-ring with a long nose plier.

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INSPECTION 3. Measure outer diameter of armature commutator.
ARMATURE CHECK If the measured value is less than limit, replace the
1. Coil short test armature.
a. Place the armature on a growler tester. Hold a * Limit value : Ø 35.0mm
piece ofiron in parallel with the armature.
b. Slowly turn armature by hand. If the iron piece is
attracted or vibrated, which means there is a
short circuit. Then, replace the armature.

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4. Measure under cut (B) between segment (A). If out of

reference value, correct it.
* Reference value : 0.7 ~ 0.9 mm
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2. Coil ground test

Check for continuity between the commutator and
shaft (or core). If there is continuity at the place
where coil is grounded, replace the armature.

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5. Commutator check FIELD COIL CHECK
a. Place the armature on 2 V-blocks. Measure the 1. Coil open test
run-out of commutator using a dial indicator. Check for continuity between the terminal lead and
b. If the run-out exceeds the limit, repair it as far as the brush (+). If there is no continuity, the circuit is
outer diameter does not exceed the service limit. opened. Then, replace the yoke assembly.
c. Repair the irregular wear on the commutator
surface by grinding with sand paper (No.
300~ 500).
* Commutator run-out : 0.06 mm

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2. Coil short test

Check for continuity between the yoke and the brush
(+). If there is continuity, the circuit is grounded.
SDFEE7058D Then, replace the yoke assembly.

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BRUSH AND BRUSH HOLDER ASSEMBLY 3. Brush holder assembly insulation test
1. Measure the brush wear, and replace ifi t is less than Check for continuity between brush holder (+) and
the limit. brush holder plate (-). If there is continuity, replace
When replacing the brush, take care not to damage the brush holder assembly.
brush.
* Brush wear service limit : 12.0 mm

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2. Measure the installed load of the brush spring.

If the measured spring pressure is less than the limit,
replace the spring.
* Reference value : 20 ~ 24 N(2.1~ 2.4kgf)

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MOTOR INSPECTION Holding coil support Test in the magnetic
ELECTRIC MOTOR OPERATION TEST switch
1. Connect battery between terminal “M” of magnetic 1. Pull out the pinion to 34mm by hand with battery
switch and motor body. connected between terminal “S” of magnetic switch
and body. If pinion returns when it is released,
2. It is normal if the electric motor operates. Check the
holding coil is normally functioning.
internal parts if the electric motor does not operate.
◆ Do not try to connect continually longer than 10
◆ Do not try to connect continually longer than 10
seconds.
seconds.

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Magnetic switch return test
Pull-in coil test in the magnetic switch
1. Pull out the pinion to 34mm by hand with battery
1. Pull-in coil is normal if the plunger goes in and then
connected between terminal “M” of magnetic switch
the pinion comes out when the battery is connected
and body. If pinion returns immediately when it is
between terminal “S” and “M” of magnetic switch.
released, both coils are normally functioning.
2. Ifi t does not come out, replace the magnetic switch.
◆ Do not try to connect continually longer than 10
Disconnect connector from terminal "M" for the test.
seconds.
◆ Do not try to connect continually longer than 10
seconds.

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