Gear clearance adjustment
1. Disconnect the wire from terminal M.
2. Connect the battery terminals to the S and M terminals with additional wires.
3. Turn the ignition on and the starter gear will move forward.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
4. Use a feeler gauge to check the clearance between the gear and the stopper. 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: 0.5-0.2mm
Check of the traction relay of a starter
1. Disconnect the wire from terminal M.
2. Connect the battery terminals to the S and M terminals with additional wires.
3. Turn the ignition on and the starter gear will move forward. 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
1. Disconnect the wire from terminal M.
2. Connect the battery terminals with the S terminal and the traction relay housing with additional wires.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
3. If the gear remains in place, then the holding winding of the traction relay is damaged and the traction relay must be replaced.
Checking the return of the traction relay plunger
1. Disconnect the wire from terminal M.
2. Connect the battery terminals with the M terminal and the traction relay housing with additional wires.
Warning! This check must be carried out within 10 seconds, otherwise the traction relay coil may burn out.
3. The starter gear should move forward. After disconnecting the wires, the starter gear should quickly return to its original position.
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 reads 11.5 volts while checking the current drawn by the starter and making sure the starter shaft turns easily and smoothly.
Current: no more than 60 A
Overrunning gear
1. To remove the freewheel from the rotor shaft, you must first remove the thrust ring.
2.Move the thrust ring to the gear and remove the snap ring. The thrust ring can now be removed from the shaft.
Checking the rotor winding
1.Use an ohmmeter to check the continuity between the collector and the rotor. If there is continuity, replace the rotor.
2.In a special device, check the rotor winding.
If there are short circuits, replace the rotor. If the steel strip attached to the rotor vibrates, then there are short circuits in the rotor windings.
3.Use an ohmmeter to check continuity between the manifold segments. If there is no continuity, replace the rotor.
Checking the stator coils
1.Check the continuity of the stator coils with an ohmmeter. If there is no continuity, replace the stator coils.
2.With the coil installed in the housing, check for continuity between the coil lead and the starter housing. If there is continuity, replace the stator coils.
Checking the brushes
If the brush is worn to the indicated limit, replace it.
Checking the brush holder
Using an ohmmeter, check the continuity between each insulated brush and plate. If there is continuity, replace the brush holder.
Overrunning clutch test
Check the condition of the freewheel gear teeth and replace if damaged. Also check the condition of the flywheel gear teeth.
Check gear. The gear should turn freely clockwise and lock when turned counterclockwise
Brush replacement
1. Remove the worn brush, being careful not to damage the braided wire.
2. Sand the end of the braided rein with sandpaper to ensure it makes good contact with the new brush.
3. Solder the braided wire.
Rear hub replacement
1. Before removing the sleeve, it is necessary to measure the depth of its installation.
2. The bushing can be removed with a puller as shown in the figure.
3. Install the new bushing to the previously measured depth.
Starter Assembly
1. Install a freewheel onto the front end of the rotor shaft.
2. Install the snap ring and snap ring on the front side of the rotor shaft, then move the snap ring all the way to the snap ring.
3. When installing the lever in the front cover, pay attention to its position. If the lever is set the other way around, the gear will be constantly pushed outward and will not work properly.