Using an ohmmeter, measure the resistance between the wire terminal and the brush wire as shown in the figure.
If the resistance tends to infinity, i.e. circuit is open, replace the starter housing assembly with the stator winding.
2. Check if there is a short circuit in the stator winding "to ground".
Measure the resistance between the stator winding and the housing.
If the resistance is low, then replace the starter housing assembly with the stator winding.
Checking the brushes
Using a caliper, measure the length of the brush.
Standard length:
- Type 2.0 kW - 15.0 -15.5 mm
- Type 2.2 kW - 16.5 - 17.0 mm
- Types 2.5 and 2.7 - kW 20.5 - 21.0 mm
Minimum length:
- 2.0 kW and 2.2 kW types - 9.5 mm
- 2.5 kW and 2.7 kW types - 13.0 mm
If the length is less than the minimum allowable value, then replace the brush holder.
Checking the brush spring
Use the steelyard to measure the tension of the brush springs at the moment of their separation from the brush.
Nominal force of brush springs:
- Type 2.0 kW and 2.2 kW - 2.7-3.3 kg (26-32 N)
- 2.5 kW and 2.7 kW types - 3.2-4.0 kg (31-39 N)
If the spring force is out of specification, replace the brush springs.
Checking the brush holder Check the insulation of the brush holder. Using an ohmmeter, check that the resistance between positive "+" and negative brush holder tend to infinity, i.e. circuit is open. If the resistance is "0", i.e. the circuit is shorted, replace the brush holder.
Checking the freewheel and gears
1. Inspect the running surfaces of the drive and idle gear teeth and the freewheel gear for excessive wear or chipping.
If worn or damaged, replace the gears or the entire freewheel assembly.
If there are scores or chips on the surfaces of the teeth of the drive gear, check the working surfaces of the teeth of the flywheel ring gear.
2. Check freewheel.
Check that the drive gear rotates clockwise freely and counterclockwise does not rotate.
3. Type 2.0KW
If necessary, replace the clutch assembly.
A. Disassemble the starter housing and clutch assembly.
A) Push the drive gear down.
b) Using a plastic-faced hammer, lightly tap the lock washer.
V) Using a screwdriver as a lever, remove the circlip.
G) During disassembly, remove the following items:
- (1) lock washer,
- (2) drive gear,
- (3) spring,
- (4) starter housing,
- (5) bearing cage,
- (6) spring holder,
- (7) starter clutch,
- (8) spring,
- (9) clutch shaft.
B. Assemble clutch and starter housing.
A) In the first step, collect the following items:
- (1) clutch shaft,
- (2) spring,
- (3) starter clutch,
- (4) spring holder.
b) In the second step, collect the following items:
- (1) starter shaft and clutch
- (2) bearing cage,
- (3) starter housing,
- (4) spring,
- (5) drive gear,
- (6) lock washer.
V) Click on the drive gear and lower it down.
G) Using circlip pliers, install the circlip.
d) Using pliers, compress the circlip.
e) Check that the snap ring is seated correctly.
and) Using a plastic-faced hammer, lightly tap the clutch shaft into place and install the lock washer onto the circlip.
Bearing check
1. Check the condition of the bearings. Manually rotate each of the bearings, applying an inward force to it.
If resistance is felt or the bearing seizes, replace the bearing.
2. If necessary, replace the bearings.
A. Remove the bearings.
Using the special tool, remove the bearing.
B. Install bearings.
Front bearing - type 2.0 kW
A) Using a 10mm nut and a press, press on the new bearing.
b) Using a center punch, caulk the nut.
Front bearing - 2.5 kW and 2.7 kW types
Using a press, press on the new bearing.
Rear bearing
Using a drift and a press, press on the new bearing.
Checking the traction relay
1. Check for an open in the pull-in winding circuit. Measure the resistance between the terminals with an ohmmeter "50" And "WITH".
If the resistance tends to infinity, i.e. circuit is open, replace the traction relay.
2. Check for an open in the holding winding circuit. Use an ohmmeter to measure the resistance between the terminal "50" and traction relay housing.
In the absence of conductivity, i.e. if the resistance tends to infinity, replace the traction relay assembly.