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ST-7
STARTING - STARTER
ST083-04

INSPECTION
1. INSPECT ARMATURE COIL COMMUTATOR FOR
OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
Continuity
ST0663

2. INSPECT ARMATURE COIL COMMUTATOR FOR
GROUND
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, correct with sandpaper (No. 400)
No Continuity or a lathe.
ST0664

4. INSPECT COMMUTATOR CIRCLE RUNOUT
Dial Gauge (a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.

Z03211

5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter: 28.0 mm (1.102 in.)
Minimum diameter: 27.0 mm (1.063 in.)
If the diameter is less than minimum, replace the armature.

Vernier Calipers

Z03209

6. INSPECT COMMUTATOR UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

ST0040

2002 ECHO (RM884U)

Author : Date : 835
ST-8
STARTING - STARTER

7. INSPECT FIELD FRAME (FIELD COIL) FOR OPEN CIR-
CUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.

Continuity
ST0666

8. INSPECT FIELD FRAME (FIELD COIL) GROUND
Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.

No Continuity
ST0665

9. INSPECT BRUSH LENGTH
Vernier Calipers Using vernier calipers, measure the brush length.
Standard length: 14.0 mm (0.551 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush (field frame
side) or brush holder, and dress with an emery cloth.

ST0648

10. INSPECT BRUSH SPRINGS
Check the brush spring load.
Take the pull scale reading the instant the brush spring
separates from the brush.
Spring installed load:
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
Minimum spring installed load:
Brush 8.8 N (0.9 kgf, 2.0 lbf)
ST0019 If the installed load is not as specified, replace the brush
springs.
11. INSPECT BRUSH HOLDER
No Continuity Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.

ST0660

2002 ECHO (RM884U)

Author : Date : 836
ST-9
STARTING - STARTER

12. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the planetary gear, internal gear
and starter clutch for wear or damage.
If the gear is damaged, replace it.
If the starter clutch teeth are damaged, replace the starter
clutch and also inspect the flywheel ring gear for wear or dam-
age.

(b) Check the starter clutch.
Free Rotate the clutch pinion gear clockwise and check that it
turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
If necessary, replace the starter clutch.

Lock

ST0661

13. INSPECT MAGNETIC SWITCH
(a) Check the plunger.
Push in the plunger and release it. Check that it returns
quickly to its original position.
If necessary, replace the magnetic switch.

ST0667

(b) Check the pull-in coil for open circuit.
Terminal C
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.

Terminal 50

Continuity
P25604

(c) Check the hold-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
Switch If there is no continuity, replace the magnetic switch.
Body

Terminal 50

Continuity
P25605

2002 ECHO (RM884U)

Author : Date : 837
ST-10
STARTING - STARTER

14. INSPECT BEARING
(a) Check the planetary carrier shaft.
Using a micrometer, measure the outer diameter of the
Micrometer surface in contact with the center bearing of the planetary
carrier shaft.
Standard shaft diameter:
14.980 - 15.000 mm (0.5898 - 0.5906 in.)

ST0649

(b) Check the center bearing.
(1) Using a caliper gauge, measure the inside diameter
of the center bearing.
Center bearing inside diameter:
15.008 - 15.050 mm (0.5908 - 0.5925 in.)
(2) Subtract the planetary carrier shaft diameter from
the bearing inside diameter measurement.
Standard center bearing oil clearance:
Caliper Gauge 0.01 - 0.06 mm (0.0004 - 0.0024 in.)
ST0650

Maximum center bearing oil clearance:
0.2 mm (0.0078 in.)
If the clearance is greater than maximum, replace the planetary
carrier shaft and center bearing.

2002 ECHO (RM884U)

Author : Date : 838

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