- key "for 8"
- screwdriver
- electric soldering iron
Starter: 1 - cover on the drive side; 2 - drive gear; 3 - armature shaft; 4 - body; 5 - cover from the side of the collector; 6 - traction relay
1. Unscrew the nut of the lower contact bolt of the starter traction relay...
2.... remove the washer and disconnect the tip of the stator winding output.
3. Loosen the two nuts securing the starter traction relay (one is shown).
4. Remove the traction relay from the cover on the drive side.
5. Remove the anchor of the traction relay from the cover on the drive side, disengaging it from the drive lever.
6. Remove the stop of the drive lever by prying it with a screwdriver.
7. Loosen the two pinch bolts and...
8.... remove the casing from the cover on the manifold side.
9. Remove the cover gasket.
10. Remove the brush springs from the brush holder.
11. Remove the lock washer from the starter armature shaft and...
12....adjusting washers.
13. Separate the starter housing and manifold side cover (if this cannot be done by hand, use a screwdriver).
14. Remove the insulated brushes from the brush holder and...
15.... remove the starter cover from the collector side.
16. Remove spacer from armature shaft.
17. Remove the cotter pin that secures the starter drive lever axle, and...
18....remove the axle from the cover on the drive side.
19. Remove the drive side cover.
20. Remove the starter drive lever.
21. Remove the starter anchor from the housing.
22. Slide the stop ring off the lock ring.
23. Remove the circlip and stop ring from the armature shaft.
24. Remove the starter drive clutch assembly from the armature shaft.
25. Remove the spring from the traction relay.
26. To replace the brushes, remove the insulating clip...
27.... heat the junction of the insulated brushes with the stator terminal with a soldering iron and, opening the bend of the stator terminal with a screwdriver...
28....remove the insulated brushes.
29. Loosen the screws securing the bar tips of the non-insulated brushes and remove the brushes from the cover on the collector side.
Troubleshooting starter parts
30. Check the condition of the stator winding. To do this, turn on the control lamp (rated for 220 V) into a 220 V AC network and connect one wire to one of the stator winding terminals, and short the other to the case. If the lamp is on, the winding insulation is damaged. Replace winding or stator. Also check the other stator winding. Be careful when testing with 220V. Do not touch live parts of the stator with your hands.
31. Inspect the surfaces of the armature shaft under the bearings. If a yellow coating from the bearings is found on the armature shaft, remove it with a fine sandpaper. There must be no damage on the surface of the shaft splines (scuffing, nicks, chipping of teeth and visible signs of wear).
32. Check the reliability of the soldering of the armature winding leads to the collector plates.
33. The starter housing seal must not be damaged (breaks, cracks, etc.).
34. Check the starter drive by turning the gear (it should only rotate in one direction). If drive parts are severely worn or damaged, replace drive. If nicks are found on the lead-in part of the teeth, grind them with a fine-grained circle of small diameter.
35. Check the condition of the traction relay armature spring. Replace broken spring.
36. The starter coupling bolts must not have severe damage to the threaded part and heads.
37. Check the condition of the starter cover on the drive side. Cracks are not allowed.
38. Inspect the surface of the traction relay armature. Deep risks and bullying are not allowed. the armature should move easily in the traction relay, without jamming.
39. The starter lever forks must not be bent.
40. Check the condition of the starter brushes by measuring their height. It must be at least 12 mm.
41. Check the closure of the contact bolts of the traction relay with a plate. To do this, connect an ohmmeter to the contact bolts and press the rod of the traction relay (flange side). If the ohmmeter shows "infinity", replace the traction relay.
42. Check up a condition of an internal surface of the traction relay. Risks, teases, etc. not allowed.
Starter Assembly
Assemble the starter in the reverse order of disassembly, taking into account the following features.
43. Clean the surface of the starter armature manifold.
44. Lubricate the splined part of the armature shaft with engine oil...
45....bearing-sleeve cover on the side of the collector and...
46.... the sliding surface of the starter drive.
47. Press in the restrictive ring after installing the retaining ring on the armature shaft.
48. Lubricate the drive ring of the starter drive with Litol-24 grease.