To remove the starter motor, first disconnect the battery negative lead and the leads from the starter motor, then unscrew and remove the two mounting bolts to withdraw the starter. For dismantling, clean away external dirt and prepare to test the unit; if the starter motor has high mileage, it may be more economical to replace the entire unit rather than individual components. Release the connector from the solenoid A terminal, extract the two solenoid mounting screws, and withdraw the solenoid. Remove the two tie bolts to pull the yoke from the armature, then carefully take out the armature and shift lever from the front housing, noting their orientation. Extract the two screws to remove the rear housing and the brush holder. Use a piece of tubing to drive the pinion stop down the shaft to expose the circlip, then extract it and remove the stop and overrunning clutch from the armature shaft. Check for wear between the armature shaft and its bearings, renewing them if necessary. Clean the commutator with a fuel-moistened cloth, polish if discolored, and undercut the insulators if they are level with the segments. If the commutator's outside diameter is less than 1.4842 in (37.7 mm), renew the armature. For testing, check for earthing and open circuits in the armature and field coil using a circuit tester, renewing components as needed. Test the solenoid by pushing the plunger and checking for continuity between the M and B terminals. Renew worn brushes below 0.453 in (11.5 mm) and check the brush holder for continuity. Inspect the overrunning clutch and pinion for wear, ensuring the pinion rotates freely clockwise but locks anticlockwise. For reassembly, fit the clutch/pinion to the armature shaft, followed by the pinion stop and circlip, then the small washer to the front end of the armature shaft. Engage the shift lever with the armature shaft and locate the assembly in the front housing, reconnect the yoke, and fit the brush holder and brushes carefully. Fit the washer to the rear of the armature shaft, attach the rear housing, and tighten the two tie bolts. Engage the shift lever with the solenoid plunger and fit the solenoid, leaving the M terminal connector disconnected. Check the pinion to stop clearance by connecting a 12V supply between the solenoid S terminal and the starter motor body, ensuring the gap between the pinion and housing stop is between 0.020 and 0.079 in (0.5 and 2.0 mm), adjusting as necessary. Reconnect the M terminal connector on the solenoid, and refit the starter motor by reversing the removal process.
