Starter

00100018
© 2004 DENSO CORPORATION
All Rights Reserved. This book may not be reproduced
or copied, in whole or in part, without the written
Permission of the publisher.
 TABLE OF CONTENTS
1. GENERAL DESCRIPTION OF STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1. OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. STARTER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-3. HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. STARTER PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. TORQUE GENERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. SERIES MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. ENGAGEMENT AND DISENGAGEMENT WITH ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. PINION SHIFT TYPE (GA TYPE) STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. PINION SHIFT TYPE (GA TYPE) STARTER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-3. INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-4. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4-5. Magnetic Switch Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4-6. PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5. REDUCTION TYPE (R, RA TYPES) STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-1. CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5-2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6. REDUCTION TYPE (R, RA TYPES) STARTER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6-2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6-3. PARTS INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6-4. Magnetic Switch Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6-5. ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6-6. PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6-7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7. PLANETARY TYPE (P TYPE) STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7-1. CONSTRUCTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8. PLANETARY TYPE (P TYPE) STARTER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8-1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8-2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8-3. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8-4. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8-5. Magnetic Switch Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8-6. PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8-7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9. PLANETARY SEGMENT TYPE (PS TYPE) STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9-1. CONSTRUCTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10. PS TYPE STARTER REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10-2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10-3. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10-4. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10-5. Magnetic Switch Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10-6. PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
10-7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
11. Heavy-Duty Planetary Type (P Type) Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
11-1. CONSTRUCTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
12. Heavy-Duty Planetary Type (P Type) Starter Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12-1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
12-2. DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
12-3. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
12-4. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
12-5. Magnetic Switch Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12-6. PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
12-7. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1. GENERAL DESCRIPTION OF STARTING SYSTEM
1-1. OUTLINE
• A battery powered DC motor starts the engine. This motor is called a "starter".

Ignition Switch

Battery

Starter

E008791E

• The internal combustor (engine) in an automobile will not start under its own power unless the engine crankshaft is ro-
tated above a certain speed by an external force.
• The role of the starter is "to rotate the engine above the minimum speed required to start the engine". Its difference to
normal DC motors is that it is only used for a short time (rated at 30 seconds). It is thus designed to be very small despite
its large output.
• A relatively large amount of force is required to rotate the engine. The starter pinion gear (small number of teeth) engages
the engine ring gear (large number of teeth) to increase engine starter torque.
• Usually, the gear ratio between the pinion gear and ring gear is about 1:15. If these gears are left engaged after start-
up, the engine will rotate the starter pinion gear, causing the pinion gear to rotate extremely quickly.
For this reason, the pinion gear must engage only during start-up, and must be disengaged as soon as possible after the
engine has started.
• Starter construction can thus be broadly divided into the "motor assembly" and the "engine engagement and disengage-
ment mechanism".

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1-2. STARTER TYPES
A. Pinion Shift Type (F, G, GA Types)
• In the GA type starter, the force of the magnetic switch (via
the drive lever) pushes the pinion gear outwards, engaging Magnetic Switch
Bolt
it with the engine ring gear. Drive Spring
Drive Lever
• The G type starter is a smaller and lighter version of the F
Drive
type starter. Operation and construction are basically the Housing
same. Brush
Pinion
Gear

End Frame
Armature
Yoke
Clutch
Stop Collar E008794E

B. Reduction Type (R, RA Types)

R/RA type starters use a compact, high-speed motor to de-
celerate the armature rotation speed by 1/3 to 1/4, and ro- Armature
tate the pinion gear. These types of starter are extremely Motor
compact.

Magnetic Switch

Pinion Gear E011745E

C. Planetary Type (P, PA Types)

The P type starter uses the same type of compact, high-
speed motor as the reduction type, but it uses a planetary Magnetic Switch
gear as the deceleration mechanism.

Motor
Planetary Gear
Pinion Gear E008795E

-2-
D. PS Type Starter
This starter uses uncoated, angular wire armature coils for
a compact and lightweight design with high output and high Magnetic Switch
efficiency. (Uncoated, angular wires are used instead of
the conventional coated electric wires, increasing both coil
Armature
density and torque.) Pinion Gear

Planetary Gear

Shaft Motor

<Cantilever Type PS Starter> E008797E

E. P Type Starter (Planetary Type): Heavy-Duty Type

A planetary gear is used as the deceleration mechanism in
conventional heavy-duty F type starters.
Magnetic Switch

Needle
Bearing Brush

Pinion Gear
Clutch Armature Field Coil
Planetary Gear Shunt Coil
E008796E

-3-
1-3. HISTORY
• As vehicle technology has progressed, starters have become more compact and lightweight, with improved perfor-
mance. Development trends are shown below.
A. Trends
• In the pinion shift type starter, the force of the magnetic
switch (sent via the drive lever) pushes the pinion gear out-
Trends Towards Compact and Light Design
wards. (kg)
15
• The change from the F type starter to the reduction type F Type 1.4kW (Output: 1.4kW Class)

starter with deceleration function drastically reduced start-

er size. Further design changes to the R type produced an 10
R Type 1.4kW

Weight
even lighter and more compact starter, known as the RA Deceleration
Construction
PS Starter
Adopted Inter-Pole Magnet
RA Type 1.4kW
type. 5
Placed Between
Main Magnetic Poles
High Deceleration
Ratio Adopted
• In 2001, the latest technology was used to produce the PS Angular Conductor
Adopted

type starter, the most compact and lightweight design yet.

0
1970 1980 1990 2000 Year
E008792E

Decade 1970s 1980s 1990s Present

Type

F Type 1.4kW (Weight R Type 1.4kW (Weight RA Type 1.4kW (Weight PS Type 1.6kW (Weight
12.5kg) 5.4kg) 3.6kg) 2.9kg)
Features • Pinion gear pushed out • Deceleration construction • High deceleration ratio • Inter-pole magnets
by the drive lever. allows a more compact and heat resistant wires placed between the main
• Spiral brush spring con- and lightweight starter. allows a more compact magnetic poles of the
struction. • Pinion gear direct shift and lightweight motor. yoke allow a more com-
• Aluminum end frame. system improves durabili- • Magnetic switch made pact and lightweight de-
ty. more compact and light- sign.
weight. • Use of angular conduc-
tors in the armature coil
allows a more compact
and lightweight design.

-4-
2. STARTER PRINCIPLES
2-1. TORQUE GENERATION
• The principles of the DC motor are explained by Fleming's
left-hand rule. The direction of electromagnetic force acting
on a conductor in a magnetic field is represented by the left Force
hand. If there is a conductor placed in the magnetic field Magnetic Field

flowing in the direction of the forefinger, current flows in the

direction of the middle finger. Force is thus generated in the
Current
direction of the thumb.
• The strength of the force is proportionate to the strength of
Force
the magnetic field and the current flowing to the conductor.
It is at its maximum when the magnetic field and the current Current
are perpendicular to each other. The strength of the force Magnetic
Field
is also proportionate to the length of the effective conductor
(length of the part affected by the magnetic field). N S
• If the strength of the magnetic field is B, the length of the EP0979E

conductor in the magnetic field is L, and the current flowing

to the conductor is I, the force F that works on this conductor is F = K x B x L x I (K is constant).
• However in order for it to work as a motor, this force must
be generated continuously, and always in a constant direc-
tion. To achieve this, a conductor is positioned on the N Field Coil

(north) pole side or S (south) pole side of the commutator Direction of Rotation

and brush so that current always flows through the conduc-

N Current S
tor in the same direction. The coil generates force in a con-
stant direction, and rotates continuously. - + Armature Coil
• The diagram on the right shows an example of a starter
Battery
with two poles and one armature coil. Actual starters have Commutator
Brush E008798E
four poles (six on heavy-duty types), with an increasing
number of armature coil and commutator combinations.
This increases the smoothness and power of the rotation.
2-2. SERIES MOTOR
• In a "series connection" type, the field coil and armature
are connected in series. This generates an extremely large
Armature
torque when rotation starts. This motor is therefore suitable
for starters which have to rotate large engines.

Field Coil

EP0981E

A. Torque
• Normally, torque is expressed by the following formula.
• T = K × ϕ × I (T: Torque, ϕ: Magnetic flux amount, I: Armature current, K: Proportionality Constant)
• The armature current is greatest when rotation starts, and current decreases as rotation increases. Because of this, very
high torque is generated during start-up.

-5-
B. Output
• Starter output is defined as the amount of work that the
starter performs every second (force × speed).

Voltage
Torque
Torque
Output
Speed
• This is expressed by Output (W) = 1.03 × Torque x Rotation
speed (kW).

N·m

Current (A) E011746E

2-3. ENGAGEMENT AND DISENGAGEMENT WITH ENGINE

• The "engine engagement and disengagement mechanism" in the starter smoothly engages (meshes) the pinion gear
with the engine ring gear, and quickly disengages after start-up.
A. Engagement
• When the starter switch is turned ON, the magnetic switch contact closes and armature rotation begins. At the same time,
the plunger is pulled in, and the pinion gear is pushed out forwards by the drive lever, engaging it to the ring gear.

Magnetic Switch

Drive Lever

T
Pinion Gear
Armature

Ring Gear

Spiral Spline

T T T
F F F T
F
A B C D

E011747E

• However, sometimes the pinion gear and ring gear do not engage smoothly and will collide. When this happens, the two
forces "T" and "F" are required to make the two gears engage properly.

T: Starter Rotation Speed

F: Pinion Gear Push Force (1) Magnetic Switch Power
(2) Thrust from Armature Spiral Spline E008994E

• These two forces cause the pinion gear contacting the ring gear to slide as shown in B to D, and engage with the ring
gear.

-6-
a. Role of the Spiral Spline
A spiral spline is cut into the armature shaft (on the drive shaft in the deceleration type). Even if the pinion gear only
slightly engages with the ring gear, the torque of the armature moves the pinion gear forward, engaging it properly. This
thrust also assists the forward push action of the magnetic switch, enabling the magnetic switch to be made more com-
pact.
b. Cranking
Starter torque is transmitted from the pinion gear to the ring gear, and the engine is crank started.
c. Disengagement
When the starter switch is turned OFF, the magnetic switch plunger returns, the pinion gear disengages from the ring
gear, and the armature stops rotating.

-7-
3. PINION SHIFT TYPE (GA TYPE) STARTER
3-1. CONSTRUCTION
• The pinion shaft type starter is constructed from an armature that makes up the motor assembly, a field coil that creates
a magnetic field, and a brush through which current flows to the armature. Engagement and disengagement with the
engine ring gear is performed by the magnetic switch. The magnetic switch moves the clutch via the drive lever.
*1: The G, GA type starters are smaller and lighter versions of the F type starter. Operation and construction are basically the same.

Magnetic Switch
Bolt
Drive Spring

Drive Lever

Drive Housing

Brush
Pinion Gear

End Frame

Armature

Yoke

Clutch
Stop Collar E008800E

A. Yoke
• The yoke consists of the pole core, brush, and field coil.

Yoke Housing Brush

Pole Core Field Coil

EP0984E

• The field coil is directly wound around the pole core, which
is fixed to the yoke. It is secured with plastic, and this im-
proves heat resistance and vibration resistance.

EP0985

-8-
 B. Armature
The armature consists of parts such as the core (iron),
shaft, coil and commutator. The whole of the armature coil Commutator
is secured with plastic, improving heat resistance and vi- Armature Coil
bration resistance. A spiral spline is also cut into the shaft.

Armature Shaft

Armature Core

Spiral Spline E008801E

C. Clutch
a. Role of the Clutch
The role of the clutch is to prevent damage caused by ar-
mature overrun from the engine rotation. In addition, it Spline Tube
Clutch Roller
helps ensure smooth disengagement of the pinion gear.

Outer

Stop Collar

Spring
Inner
Pinion Gear E008802E

< NOTE >

• Overrun
"Overrun" means that when the pinion gear fails to disengage from the ring gear after the engine starts, the engine ro-
tates the armature at high speed.
b. Construction
• The main parts of the clutch are the inner (integrated with the pinion gear), outer (integrated with the spline tube), clutch
roller and spring.
• One end of the space that stores the clutch roller is narrower than the other. The clutch roller is kept pushed against the
narrow end by the spring force.
c. Operation
(1) During Start-Up
When armature rotation is transmitted through the spline
tube to the outer, the outer rotates in the direction of the ar- Clutch Roller
row. The spring force presses the clutch roller into the nar-
row end of the space between the outer and the inner. This
locks the outer and inner together. The roller acts like a Inner
wedge between the inner and outer, and transmits outer ro- (Integrated
Outer with Pinion
tation to the inner, making both parts rotate at the same (Integrated Gear)
speed. with Spline
Tube)
Pinion Gear
(Outer and Inner are Locked) E008803E

-9-
(2) After Engine Start-Up
When the ring gear rotates the pinion gear, the inner rota-
tion (engine rotation × gear ratio) becomes faster than the
outer rotation (armature rotation). Because this moves the Outer
Clutch Roller
clutch roller in a direction to compress the spring, the outer
and inner lock is released, preventing armature overrun.
Inner
(Contact pressure on the pinion gear and ring gear contact
surface must be reduced to ensure smooth disengagement
of the pinion gear. Therefore, the pinion gear must be
idling.) Pinion Gear
(Outer and Inner are Free) E008804E

D. Magnetic Switch
• The magnetic switch pushes out and pulls in the pinion
gear, and turns the motor circuit main contact ON and OFF. Return Spring
• The switch is constructed from parts such as the pull-in
coil, holding coil, return spring and plunger, as shown in the
diagram on the right. Plunger

• The number of windings in the pull-in coil and holding coil

are the same, but the thickness of the wires (resistance)
Main
differs. The pull-in coil has thick wires, and thus generates
Contact
a large magnetomotive force, while the holding coil has thin
wires, with a small magnetomotive force. Pull-In Coil
Holding Coil E008805E

a. Operation
(1) Turning the Starter Switch (S.S.) ON
When the starter switch S.S. is closed, current flows along two circuits as shown in the diagram below. The plunger is
pulled in by the combined magnetic force of the pull-in coil and holding coil, and this closes the main contact M.S.

P.C A F
B S.S E
H.C .......................

C M.S M

S.S B
A P.C
Battery

50

H.C
F

E E
E008806E

-10-
(2) During Start-Up
When the main contact M.S. is closed, the pull-in coil is
short-circuited by the contact, so current stops flowing to C M.T
M.S
the pull-in coil. However, once the plunger is pulled in, the
air gap between the moving core (the plunger) and the coil S.S B
P.C
decreases (magnetic resistance is reduced), and the A

Battery
50
plunger is held only by the magnetic force of the holding
coil. H.C
F

E Plunger E008807E

(3) Starter Switch OFF

If the starter switch opens while the main contact is closed,
a circuit is created from "B" -> "M" -> "M.S." -> "P.C." ->
C M.S M
"H.C." -> "E", and current flows to both the pull-in coils and
holding coils in series. As a result, the state of the direction S.S B
of the pull-in coil magnetic force during start-up is reversed, P.C
A

Battery
and holding coil magnetic force is negated. The plunger is 50
returned by the force of the return spring, and the main con-
H.C
tact opens. F

E
E008808E

-11-
3-2. OPERATION
• In this section, individual explanations are linked to describe operation of the starter as a whole.
A. Starter Switch ON
• Current flows to both the pull-in coil and holding coils, and
the plunger is pulled in by the generated electromagnetic Starter Switch
force of both coils.
Drive Lever H.C P.C
• The pinion gear is thus pushed out to the left, and it engag-
es with the ring gear.
Pinion Gear
Plunger

Ring Gear E008809E

a. When the Pinion Gear Engages with the Ring Gear Without Collision
• When the pinion gear engages with the ring gear to a cer-
tain position, the magnetic switch main contact closes, and Starter Switch
a large current flows through the main contact to the arma-
H.C P.C
ture.
Clutch
• The force of the armature spiral spline pushes the pinion
Pinion Gear
gear forward, and it engages with the ring gear to crank the
engine.

Ring Gear Armature E008810E

b. When the Pinion Gear and Ring Gear Teeth Collide

If the pinion gear and ring gear teeth contact, the pinion
gear cannot move any further. If this happens, the mag-
Starter Switch
netic switch drive spring compresses, and the magnetic Drive Spring
switch contact closes. This rotates the armature at high Drive Lever H.C P.C
torque, and the teeth alignment position slides. The com-
pression force of the drive spring and the force of the ar- Pinion Gear

mature spiral spline move the pinion gear forward, and it

engages with the ring gear to start the engine.

Ring Gear Armature E008811E

-12-
B. After Engine Start-Up
When the engine starts, the clutch idles to stop the ring gear from driving the armature in reverse.
C. Starter Switch OFF
• When the starter switch is turned OFF, the magnetic switch
attraction is cancelled and the pinion gear is returned by
Starter Switch
the magnetic switch return spring.
P.C
• The main contact opens, interrupting the flow of current to H.C
the armature.
Pinion Gear

Ring Gear Armature

E008812E

-13-
4 PINION SHIFT TYPE (GA TYPE) STARTER REPAIR

4-1. Introduction
A. Cautions for Work
a. Work Environment
(1) Clear and clean the work stand before beginning work.
(2) Do not perform work in humid, dirty or dusty places.
b. Cautions for Disassembly and Reassembly
(1) Regularly tidy the work area to prevent loss of parts.
(2) Do not secure high-precision parts tightly in a vise, or hit them with a hammer.
(3) When installing bolts and nuts, use a torque wrench and torque driver to tighten them to the values shown in the test
standards table.

B. Preparatory Items List (Not Including General Tools)

DENSO Part
Classification Part Name Remarks
Number

STT Snap Ring Pliers 95994-10050 For snap ring disas-

sembly and reassem-
bly.

E014115

DENSO No. 50 Grease 028770-0010

E014116

V Blocks 95800-10140 For armature inspec-

tion.

E014119

-14-
 DENSO Part
Classification Part Name Remarks
Number

Tool Vernier Calipers -

E011798

Dial Gauge - For armature inspec-

tion.

E014117

Growler Tester - For layer short inspec-

tions in the armature
coil.

E014118

Multimeter -

E011799

Megger Tester -

E011800

Solder (100% Tin) - The kind of solder

used impacts perfor-
mance, so always use
100% tin solder.
EC1619

Soldering Iron - Use a soldering iron of

100W or more.

EC1620

*1: STT : Service Tools and Testers

-15-
4-2. DISASSEMBLY
Disassembly procedures differ slightly according to the starter type. The GA type (12V 0.8kW) starter is described here
as an example. A number of small parts are removed during disassembly, so be careful not to lose them. They must be
stored in order so that the reassembly sequence is easily understood.

Magnetic Switch

Drive Lever

Snap Ring

Armature
Clutch

Stop Collar Pinion Gear

Front Bushing

Insulator

Drive Housing Through-Bolt

Rear End Frame

Rear Bushing

Brush Spring

Brush Holder

Yoke
E008813E

-16-
A. Magnetic Switch Removal
a. Disconnect the lead wire from the magnetic switch.

Lead Wire
Fixing Nut

E008814E

b. Remove the two magnetic switch fixing nuts, and then re-
move the magnetic switch.
Magnetic Switch

Magnetic Switch
Fixing Nut

E008815E

B. Rear End Frame Removal

a. Remove the two through-bolts.

Through-Bolts

E008816E

b. Remove the rear end frame.

Rear End Frame

E008817E

-17-
C. Yoke Removal
a. Remove the insulator.
b. Remove the four brush springs and the brush holder. Brush Holder

Insulator

Brush Spring
Brush
E008818E

c. Remove the yoke from the armature.

Yoke
E008819E

D. Clutch Removal
a. Remove the drive lever and armature.

Drive Lever

Armature E008820E

b. Secure the armature in the vise.

< CAUTION >
• Do not tighten the vise excessively.

c. Using a screwdriver, move the pinion stop collar to the

clutch side.

E011748

-18-
d. Using snap ring pliers, remove the snap ring. Remove the
stop collar and clutch.
< CAUTION >
• Do not reuse the snap ring.

E008826

4-3. INSPECTION AND REPAIR

A. Armature
a. Layer Test
(1) Using a growler tester, inspect the armature coil for
a layer short.

The thickness gauge does not attract Thickness Gauge

Standard
or does not vibrate.

< NOTE >

• If there is a short circuit in the armature coil, a cyclic cur-
rent flows due to the alternating magnetic flux of the
growler tester. This turns the short-circuited area of the
armature core into a magnet. Thus, if a piece of iron is
contacted with the core, the iron will vibrate in the short-
Growler Tester E008990E
circuited area to detect the short circuit.

< CAUTION >

• Remove particles such as carbon grains from around the commutator before inspection.

b. Insulation Test
(1) Inspect insulation between the commutator and ar-
mature core with a 500V megger tester.

Standard Value 0.1MΩ or more.

E016877

-19-
c. Commutator Run-Out Inspection
(1) Using the V-block, support the armature on the level
block. Use the dial gauge to measure the run-out as
shown in the diagram.

Standard Value 0.05mm or less.

Replacement Standard 0.4mm

E008828

d. Commutator Outer Diameter Inspection

(1) Using vernier calipers, measure the commutator ex-
ternal diameter as shown in the diagram.

Standard Value 28mm

Replacement Standard 27mm

E008829

e. Commutator Insulation Depth Inspection

(1) If insulation material between the segments is higher
than the segment surface, it will prevent rectification.
Ensure that standards are satisfied for the depth be- Insulating
Segments Material Depth
low the segment surface. Insulating
Material
Standard Value 0.6mm
Replacement Standard 0.2mm

E008995E

-20-
B. Yoke
a. Brush (Positive (+) Side) and Lead Wire Continuity Check
(1) Check continuity between the brush (positive (+)
side) and lead wire with a multimeter.

Standard Value 1Ω or less.

(-)
(+) (+)

(-)

Multimeter

E008830E

b. Field Coil Insulation Test

(1) Inspect insulation between the coil and yoke with a
500V megger tester.
(+)
(-)
Standard Value 0.1MΩ or more.

(+)
(-)

Megger Tester
E008831E

C. Brush Holder
a. Inspect the brush holder to make sure there are no
scratches or cracks.

E008832

-21-
D. Brush Spring
a. Inspect the brush spring to make sure there is no rust or
fatigue.
b. Inspect the length of the brush spring.

Standard Value 21.5mm (example).

E008833

E. Brush
a. Brush Length Inspection
(1) Inspect the length of the brush.

Standard Value 10.0mm

Replacement Standard 7.8mm

Length

E008834E

b. Brush Replacement Procedures

(1) Using nippers, cut the base (soldered end area) of
the brush lead wires on the yoke side.
Cut

Brush Lead
Wires

Nippers

E008835E

-22-
 (2) File off the solder portion on the brush lead wire with
a file.
< CAUTION > Eliminate Burrs
• The filing area is small, so be careful not to damage the
field coil.

File

E008836E

(3) Overlay the spare brush plate on the soldered area

of the brush lead wire, and press it with pliers. Align
the spare brush lead wire with the cut side.

Cut Side

Plate Spare
Pliers Brush
Pressing
E008837E

(4) Solder the pressed area.

< CAUTION >
• Apply the solder quickly to prevent it from flowing onto the
brush side lead wire. Make sure there is enough solder
around the plate. Make sure solder does not run towards
the field coil.

Soldering Iron
Solder
E008838E

-23-
F. Bushing
a. Bushing Inspection.
(1) Using vernier calipers, measure the clearance between the bushing and the shaft as shown in the diagram. Clear-
ance = bushing inner diameter - shaft outer diameter.

Example: Front Bushing

A: Inner Diameter of the Drive Housing Bushing B: Outer Diameter of the Shaft (Front Side)
Clearance = A - B E008839E

Front Bushing

Clearance
0.02 - 0.07mm
Standard Value

Replacement Standard 0.15mm

Rear Bushing

Clearance
0.02 - 0.07mm
Standard Value

Replacement Standard 0.15mm

< CAUTION >

• Do not perform reamer finishing on oilless bushing, as
this may cause seizure. Coat the bushing with engine oil
10W30 during assembly.

E008996

b. Front Bushing Replacement Procedures

(1) If clearance is 0.15mm or more, replace the bushing.
During replacement, use a jig to remove the bushing
Pressure
as shown in the diagram.
< CAUTION > Jig
• Machine the shaft until a clearance of 0.02 - 0.07mm is
obtained between the bushing inner diameter and the
shaft outer diameter. Bushing

Jig E008840E

-24-
c. Rear Bushing Replacement Procedures
(1) Cut the screw on the end frame rear bushing with the
tap (M12), as shown in the diagram.

Tap (M12)

Rear Bushing
(Oilless)

End Frame E008841E

(2) Further tighten the tap after it contacts the bottom of

the end frame to force the rear bushing upwards and
Tap (M12)
out.
End Frame

Rear Bushing
Tighten further with the tap
contacting the end frame.

E008842E

(3) Replace with new bushing. During replacement, use

a jig for press fitting as shown in the diagram. Pressure
< CAUTION >
• Machine the shaft until a clearance of 0.02 - 0.07mm is
obtained between the bushing inner diameter and the Jig
shaft inner diameter.
Bushing

Housing

E008843E

-25-
G. Front Needle Bearing Replacement
On some GA type starters, a needle bearing is used instead of a front bushing. Replacement procedures are as fol-
lows.

a. Needle Bearing Inspection

(1) Inspect the needle bearing to ensure play is not excessive, and to check that it rotates smoothly.

There is a large amount of play or the bearing does not rotate smoothly. (Replacement is
Replacement Standard
unnecessary if there is no abnormality.)

<Front Bushing> <Needle Bearing>

E008844E

b. Replacement Procedure
(1) Tools

• Hand press. <Washer Dimensions>

• Tension rod for the box wrench.
• Washer (refer to the dimensions in the diagram).
16

+0.2
1.0 - 0.2

30 E008846E

(2) Removal method: Use the hand press and tension

rod to press and remove the bearing, as shown in the
Hand Press
diagram.
Tension Rod
< CAUTION >
• Do not reuse removed bearings.

Table
E008847E

-26-
 (3) Press fitting method: Press fit the bearing with the
hand press as shown in the diagram.
Washer
Hand (GA Type Only)
Press
1mm

E008848E

c. Cleaning the Front Housing

Special grease is inserted inside the needle bearing. To prevent this grease discharging, be sure not to get cleaning
oil on the needle bearing during cleaning.

< CAUTION >

• It is not necessary to coat the needle bearing in grease.
• Coat the armature shaft with a little engine oil (10W30) to prevent any scraping when inserting the armature shaft into
the needle bearing.

(1) Cleaning method: Insert the plug as shown in the di-

agram, position the needle bearing on the upper Needle Bearing
side, and clean the front housing.
< CAUTION > Plug
• Do not place the front the front housing directly in diesel
oil. Front Housing
• Position the bearing on the upper side to clean the brush.

E008849E

(2) Machining method for cleaning plug: For the clean-

ing plug, machine and use the through-vane com-
pressor S side plug cap (no charging valve, part
number 442650-2000).

• File down the shaded area shown in the diagram A

with a grinder or file.
• Machine the installation section to the specified di- Original Dimension: 18.2

mensions as shown in the diagram. After Machining: 16.5 to 17.0

• Install an O-ring in section A. E008850E

DENSO Part Number 949142-0020

-27-
H. Clutch
a. Check that the pinion gear rotates in the same direction as
the starter, and does not rotate in the reverse direction.
b. Check there is no pinion gear wear, damage, resistance or
rust.
Lock

Free

E008854E

I. Magnetic Switch Inspection

a. Return Spring Inspection
(1) Check that the plunger quickly returns to its original
position when it is pushed down and released.

EP2895

b. Continuity Inspection
(1) Check continuity between terminal 50 and terminal
C.
Terminal C
Standard 1Ω or less.

Terminal 50

Multimeter EP2896E

(2) Check continuity between terminal 50 and the mag-

netic switch body.
Terminal 50
Standard 2Ω or less.

Magnetic Switch
Body

Multimeter
E009034

-28-
4-4. ASSEMBLY
Assembly procedures are basically the disassembly procedures in reverse. However, the required inspections and
checks must be repeated properly to ensure all procedures are fulfilled and prevent mistakes in the assembly order, which
will cause malfunctions. Precautions required during assembly are described below.

A. Cautions for Assembly

a. Applying Grease
(1) Coat sliding parts such as the drive lever, clutch and armature shaft with DENSO No. 50 grease. If the bushing on
both sides is oilless bushing, coat it with engine oil. If it is rolled bushing, coat it with grease.

Engine Oil
DENSO No. 50 Grease

DENSO No. 50 Grease

DENSO No. 50 Grease Snap Collar

DENSO No. 50 Grease

Snap Ring
DENSO No. 50 Grease

Engine Oil

Engine Oil

<Tightening Torque List>

9.82N·m (7.84-11.8N·m)
Terminal C Nut
100kgf·cm(80-120kgf·cm)
8.8N·m (7.84-9.8N·m)
Terminal M Nut 90kgf·cm(80-100kgf·cm)
8.34N·m (5.88-10.79N·m)
Magnetic Switch Installation Nut
85kgf·cm (60-110kgf·cm)
5.88N·m (4.41-7.35N·m)
Through-Bolt
60kgf·cm (45-75kgf·cm)

E008855E

-29-
b. Snap Ring and Stop Collar Assembly
(1) Place the rear side stop collar over the armature
shaft.
(2) Use snap ring pliers to place the snap ring over the Snap Ring

armature shaft and fit it into the groove. Stop Collar

(Rear Side)
(3) Tighten the snap ring to secure it.
< CAUTION >
• Always use a new snap ring.

E008856E

(4) Hold the exterior of the clutch by hand, and use a

plastic hammer to lightly tap the armature shaft and
fit the snap ring into the pinion stop collar (rear side).
(5) Insert the pinion stop collar (front side).

E008857

< CAUTION >

• Be sure to install the stop collar in the correct direction. (If the stop collar is assembled in reverse, it will directly transmit
the pinion forward force to the housing, resulting in abnormal noise.)

Coat the section with

DENSO No. 50 grease.

Groove
Pinion Stop Collar (Rear)

Armature Thrust Stop Collar (Front) Pinion

Armature Shaft

Snap Ring Always replace the snap ring with a new ring.

E008858E

-30-
c. Brush Spring Assembly
(1) Secure the shaft section of the armature in the vise.
< CAUTION >
• Do not tighten the vise excessively.

(2) Install the brush holder.

Brush Spring
(3) Install the four brush springs.
< NOTE >
• The cross-sections of the brush springs are elliptical rath-
er than circular, so they are easier to insert on their sides.

(4) Install the insulator.

E008859E

d. Drive Lever and Housing Installation

(1) Coat the contact surfaces of the drive lever and
clutch with DENSO No. 50 grease.
(2) Assemble the drive lever to the drive housing.

Coat with DENSO No. 50 grease.

E010613E

(3) Tighten the two through-bolts to install the yoke and

drive lever to the drive housing.

5.88N•m (4.41 - 7.35N•m)

Tightening Torque
60kgf•cm (45 - 75kgf•cm)

E011749

-31-
e. Magnetic Switch Installation
(1) Hang the plunger from the upper side of the drive le-
ver and install the magnetic switch.
Brush Spring

Pinion Drive Lever

E011750E

(2) Install the two nuts.

8.34N•m (5.88 - 10.79N•m)

Tightening Torque
85kgf•cm (60 - 110kgf•cm)

E011751

(3) Install the lead wire to terminal C with the nut.

9.82N•m (7.84 - 11.8N•m)

Tightening Torque
100kgf•cm (80 - 120kgf•cm)

E011752

-32-
4-5. Magnetic Switch Operation Inspection
< CAUTION >
• Perform each test in a short period of time (3 to 5 seconds).

A. Pulling-In Test
a. Remove the nut and disconnect the lead wire from terminal C.
b. With connections as shown in the diagram
Terminal 50
Battery Terminal 50 Terminal C
Battery Body and Terminal C <Current Flow>
Battery

Pinion gear springs out. Terminal 50

H.C P.C
Body Terminal C

Ground Disconnect from terminal C.

E016870E

B. Holding Test
a. From the pulling-in test conditions, remove the test wire
from terminal C as shown in the diagram. Check the pinion
gear remains out. <Current Flow>
Remove the ground wire, and verify that the pinion gear Battery
returns.
Terminal 50

H.C

Ground
EP2861E

C. Return Test
a. With connections as shown in the diagram
<Current Flow> Terminal 50
Battery Terminal C Terminal C
Battery
Battery Body and Terminal 50
Terminal C
Pinion gear springs out.
P.C
If terminal 50 is removed during this state,
the magnetomotive forces of both coils Terminal 50
will balance out. H.C
Ground Disconnect from terminal C.

The pinion gear will instantly return. E016871E

-33-
4-6. PERFORMANCE TEST

Test Item Outline

No-Load Test Observe the maximum rotation speed and current when there is no load.
Load TestObserve the required current to generate the specified torque, and the rotation speed at
Load Test
that time.
Lock Torque Test Observe the torque and current when the rotation speed is 0 during excessive load.

< CAUTION >

• Starter torque and speed varies greatly according to the battery capacity, so conduct tests with the battery properly
charged.
• A large amount of current flows during testing, so perform tests quickly.

A. No-Load Test
a. Aim
(1) Check the assembly condition.
(2) Check the main contact condition.
b. Method
(1) Connect as shown in the diagram, and close S1 to
start up the starter.
S1
(2) Measure the rotation speed, voltage and current
when starter rotation stabilizes. 50 M - +
A
(3) Perform an OK/NG judgment based on the speed.
Tachometer +
V
-

E008860E

-34-
c. OK/NG judgment method: Use the test standards and OK/NG judgment chart to judge.
< CAUTION >
• The standard values and OK/NG judgment chart vary according to the starter, so refer to the individual test standards.

(1) Current: Results are OK if the measured current is the same or less than the test standards value.
(2) Speed: Use the measured current, voltage and speed values to work out the correction speed on the judgment chart.
Judge OK if this value is the same or more than the test standards speed.

OK/NG Judgment Chart (C) No-Load Test

12.0

30
00
25
Voltage (V)

11.0

00
200
0
10.0

150
9.0 0
100
0

8.0

0 50 60 70 80 90 100 0 1500 2000 2500 3000

Test Standards Value (1900rpm)

Current (A) Correction Speed (rpm)

Example: If the measured voltage is 10V, current is 70A and speed is 2000rpm, the correction speed is 2450rpm.
E009024E

-35-
B. Load Test
a. Aim
(1) Apply the specified load and check the starter output.
b. Method
(1) Connect as shown in the diagram, and close S1 to
start up the starter. S1
(2) Apply the brake to the ring gear, and adjust until the
current matches the test standards. 50 M - +
A
(3) Measure the voltage, torque and speed at this time.
Tachometer
+
(4) Perform an OK/NG judgment based on the torque
V
value and speed. Torque Meter -

E008862E

c. OK/NG judgment method: Use the test standards and OK/NG judgment chart to judge.
< CAUTION >
• The standard values and OK/NG judgment chart vary according to the starter, so refer to the individual test standards.

(1) Torque: Results are OK if the measured torque value

is the same or more than the test standard. OK/NG Judgment Chart (B) Load Test

(2) Speed: Use the measured current, voltage and

speed values to work out the correction speed on the 9.0

judgment chart. Judge OK if this value is the same or

25
8.0

00
more than the test standards speed.

20
7.0

00
Voltage (V)

6.0

150
0

5.0
100
0
500

0 500 1000 1500 2000 2500

Test Standards Value (820rpm)

Correction Speed (rpm)
Example: If the measured voltage is 7.0V and
speed is 1500rpm, the correction
speed is 1580rpm. E009025E

-36-
C. Lock Torque Test
a. Aim
(1) Check that the specified torque is produced. (Also observe the clutch sliding.)
b. Method
(1) Connect as shown in the diagram, and close S1 to
start up the starter. S1
(2) Lock the ring gear with the brake.
(3) Measure the voltage, current and torque while it is 50 M - +
A
locked.
+
(4) Perform an OK/NG judgment based on the current V
and torque values. Torque Meter
-

E008863E

c. OK/NG Judgment Method

< CAUTION >
• The standard values and OK/NG judgment chart vary according to the starter, so refer to the individual test standards.

(1) Check the point where the measured current and torque meet on the OK/NG judgment chart shown below. OK if the
value is in the pass range. (Including points on the line.)

OK/NG Judgment Chart (A) Lock Torque Test

18

16

14 Pass
Torque (Nm)

12

10

6 Fail

0 300 400 500 600 700 800 900 1000 1100

(345A) (1035A)
Current (A)
Example: If the measured torque value is 1.2kgfm and the current is 500A Pass. E009026E

-37-
4-7. TROUBLESHOOTING
A. Preliminary Inspection
a. If starter rotation is slow, or if the starter does not rotate, preliminary inspections must be performed before inspecting the
starter itself.

• Check malfunction symptoms.

• Check the tightening state of the battery terminal (including ground wire tightening on the engine side) and starter terminal.
• Check the battery discharge condition: specific gravity, electrolyte level.
• Check the installation state of the starter.
• Inspect the fuse.

B. Malfunction Symptoms and Causes

Symptom Malfunction Cause Action

Starter does not rotate (magnetic • Poor battery specific gravity and level. • Inspect battery.
switch does not make an operating • Poor starter switch circuit connection or con- • Replace wiring and starter
noise). tact. switch.
• Malfunction of the magnetic switch pull-in coil or • Replace magnetic switch.
plunger.
Starter does not rotate (magnetic • Poor battery specific gravity and level. • Inspect battery.
switch makes an operating noise). • Poor start-up circuit contact. • Repair wiring.
• Poor contact of magnetic switch contact. • Replace magnetic switch.
• Motor assembly malfunction (e.g. layer short, • Repair or replace motor assem-
brush wear). bly.
Starter rotation is slow. • Poor contact of magnetic switch contact. • Replace magnetic switch.
• Motor assembly malfunction (e.g. layer short, • Repair or replace motor assem-
brush wear). bly.
Starter rotation cannot crank the • Pinion gear does not engage with ring gear. • Repair or replace the clutch and
engine. • Clutch sliding. drive lever.
• Replace clutch.
Abnormal noise. • Abnormal bushing wear. • Replace bushing.
• Wear on pinion gear or ring gear teeth tips. • Replace clutch and ring gear.
• Poor pinion gear sliding. • Lubricate or replace clutch.
• Pinion gear springing out. • Poor starter switch return. • Replace starter switch.
• Field coil loss. • Pinion gear disengagement fault caused by a • Replace magnetic switch.
• Magnetic switch coil burn, etc. coil layer short in the magnetic switch.

-38-
5. REDUCTION TYPE (R, RA TYPES) STARTER
5-1. CONSTRUCTION
A. Outline
The reduction starter is even more compact and lightweight than the pinion shift type starter. The term "reduction" comes
from "speed reduction". The reduction starter uses a compact and high-speed motor that decelerates the armature rota-
tion speed by 1/3 to 1/4 to drive the pinion gear. In addition, the use of heat resistant materials enables an extremely
compact and lightweight construction.

Armature

Field Coil Brush Spring

Yoke
Brush
Drive Gear

Idle Gear

Plunger

Magnetic Switch

Pinion Clutch
E008864E

-39-
 B. Construction
This explanation will concentrate on the differences to the pinion shift type starter regarding the reduction starter con-
struction.
a. Armature
Ball bearings are used because of the high rotation speed.

Bearing

Armature

Bearing

EP1005E

b. Torque Transmission
The gear decelerates armature rotation by 1/3 to 1/4 of the
pinion gear. While the rotation speed of the pinion gear is
about the same as in the conventional type, it produces in- Drive Gear
creased pinion gear torque.

Idle Gear

Armature
Pinion Gear

Clutch Gear
EP1006E

c. Clutch
(1) Construction
• The clutch is supported at both ends by bearings. The
magnetic switch plunger directly pushes out the pinion Bearing
Pinion Gear
gear through the pinion shaft.
• A pinion spring is built into the middle of the pinion gear to Pinion Spring
soften collisions during engagement, and to facilitate
engagement.
Ring
• A return spring is built into the middle of the clutch to return Gear Pinion Shaft
Clutch Gear EP1007E
the pinion gear.

-40-
(2) Operation
• Rotational torque is transmitted from the armature via the
idle gear to the clutch gear, the spline shaft, the pinion
Clutch Roller
shaft, and then the pinion gear. Pinion Shaft
• For engagement with the ring gear, the magnetic switch Pinion Gear
Plunger Shaft
plunger shaft pushes the pinion shaft forward, via a steel
ball.

Clutch Gear
Ring Gear
E008865E

d. Magnetic Switch
• The magnetic switch is constructed from a plunger, contact
plate, holding coil, pull-in coil, return spring, drive spring
Contact Plate
and core. Holding Coil
• When the starter switch is turned ON, the plunger is pulled Pull-In Coil
to the left and the plunger shaft pushes the clutch pinion
shaft out. Core
• There are two types of magnetic switch housing; aluminum
housing and plastic housing.

Drive Spring
Plunger
Plunger Shaft
Return Spring
E008866E

e. Shunt Coil
• Some RA type starters (those with outputs of 12V to 1.8kW
and 12V to 2.0kW) use a shunt coil. Terminal M
• The shunt coil is connected in parallel to the field coil and
armature as shown in the diagram. It is wound together Terminal C
with the field coil inside the yoke.
Field Coil
• Shunt coil connection suppresses the maximum rotation
speed when there is no load, and it also operates as an
Battery
electric brake when the starter switch is OFF.
• If an open circuit occurs in the shunt coil, rotation speed will
increase excessively during the no-load test.
Shunt Coil E008867E

-41-
5-2. OPERATION
• This section describes overall reduction starter operation.
A. Starter Switch ON
• Current flows to both the P.C. and H.C. coils, and the
plunger is pulled in by the generated electromagnetic Idle Gear
force. Drive Spring Armature
• The pinion gear is thus pushed out to the left, and it engag- Pinion Gear
es with the ring gear. Field Coil
Main
Contact
• When the pinion gear engages the ring gear, the main con- H.C P.C
Contact
tact closes and a large current flows to the armature. Plate
Ring Plunger
• When the armature rotates at high speed, it is decelerated Pinion Shaft Starter
Gear
by the idle gear, and rotates the pinion gear. Clutch Gear Switch
E008868E

• When the pinion gear and ring gear teeth contact each oth-
er, the pinion shaft compresses the drive spring (in the
magnetic switch) so only the pinion shaft moves, and the Idle Gear Armature

main contact closes. As a result, the thrust force of the pin- Drive Spring
Field Coil
ion shaft spiral spline slides the pinion gear into the ring
gear to engage them properly. H.C P.C

Plunger
Pinion Starter
Ring Switch
Gear Shaft
E008869E

B. After Engine Start-Up

When the engine starts, the clutch idles to prevent the ring
gear from driving the armature in reverse. The clutch prevents
high-speed rotation.
Armature
Pinion Gear
Field Coil

H.C P.C

Plunger
Starter
Ring Gear
Switch
Fast Engine Rotation
E008870E

C. Starter Switch OFF

• When the starter switch is turned OFF, the magnetic switch
attraction is cancelled and the pinion gear is returned by
Idle Gear
the return spring.
Return Spring
• The main contact opens, interrupting the flow of current to
Field Coil
the armature.
H.C P.C

Plunger Starter Switch

Ring Clutch OFF
Gear
E008871E

-42-
6 REDUCTION TYPE (R, RA TYPES) STARTER REPAIR

6-1. Introduction
A. Cautions for Work
a. Work Environment
(1) Clear and clean the work stand before beginning work.
(2) Do not perform work in humid, dirty or dusty places.
b. Cautions for Disassembly and Reassembly
(1) Regularly tidy the work area to prevent loss of parts.
(2) Do not secure high-precision parts tightly in a vise, or hit them with a hammer.
(3) When installing bolts and nuts, use a torque wrench and torque driver to tighten them to the values shown in the test
standards table.

B. Preparatory Items List (Not including General Tools)

< CAUTION >
• Refer to the "Pinion Shift Type (GA Type) Starter Repair Preparatory Items List" on page 14 for information on STT and
tools not listed below.

DENSO Part
Classification Part Name Remarks
Number

SST Bearing Puller Set 95720-00051

EC1618

Clutch Fixing Tool 95028-10121

E014137

Jig for Fixing Terminals M 95028-10130 For M8:

and C (1) 95028-10150 For M10:

E014138

Jig for Fixing Terminals M 95028-10140 For M8:

and C (2)

E014139

O-Ring Insertion Jig 95028-10160

E014140

-43-
6-2. DISASSEMBLY
Always pay full attention to the disassembly work. The RA type starter (1.4kW output) is described here as an example.

Through-Bolt
Brush Holder

Yoke
O-Ring

Rear Bearing

Armature
O-Ring
Brush

Front Bearing

Plunger

Cover

Rubber Cover
Idle Gear

Roller
Retainer

Magnetic Switch
Clutch Shaft
Coil Spring

Steel Ball

Clutch

Drive Housing E008872E

-44-
A. Disassembly Procedure
a. Yoke Removal
(1) Remove the nut and remove the lead wire from ter-
minal C.

Lead Wire

Magnetic Switch
E011754E

(2) Remove the two through-bolts from the end frame.

Through-Bolt

End Frame

E011755E

(3) Remove the armature and yoke together from the

magnetic switch.
Yoke

Magnetic Switch E011756E

-45-
b. End Frame Removal
(1) Remove the two screws tightening the end frame
and brush holder to the yoke.
End Frame

Screws
E011757E

c. Yoke and End Frame Removal

(1) Remove the end frame from the yoke as shown in
the diagram.
End Frame Yoke

E011758E

d. Brush Removal
(1) Using long nose pliers, lift up the positive (+) side
brush spring and remove the brush.
Brush
< CAUTION > Brush Holder
• Do not damage the brush or commutator.

Spring
Brush
E011759E

-46-
e. Armature Removal
(1) Remove the armature from the yoke.
Yoke Armature

O-Rings
E011760E

< CAUTION >

• Do not drop the armature.
• For R2.0/2.2 type starters, tap the end of the yoke with a
plastic hammer to remove the armature.

(2) Remove the O-rings.

< CAUTION >
• Do not reuse the O-rings.

E011761

f. Drive Housing Removal

(1) Remove the two screws tightening the magnetic
switch to the drive housing. Drive Housing

E011762E

(2) Remove the drive housing from the magnetic switch.

Magnetic Switch

Drive Housing E011763E

-47-
g. Clutch Removal
(1) Remove the clutch from the drive housing.
< CAUTION >
• For types where the pinion gear cannot be removed be- Clutch
cause it is on the outside of the drive housing, first remove
the snap ring and then remove the clutch. Refer to [9]
"Pinion Gear Replacement Method" on page 57 for de-
tails on how to remove the snap ring.
• In some starter types, the clutch cannot be removed from
the drive housing. In this case, it is not necessary to re-
move the clutch from the drive housing.

Drive
Housing E011764E

h. Steel Ball Removal

(1) Remove the steel ball from the clutch.
< CAUTION >
• Do not lose the steel ball.
Clutch

Steel Ball E011765E

i. Idle Gear Removal

(1) Remove the idle gear from the drive housing.

Idle Gear

E011766E

-48-
j. Retainer and Roller Removal
(1) Remove the retainer and rollers from the drive hous-
ing.
< CAUTION >
• Do not drop the retainer or rollers.

Retainer and
Rollers
E011767E

k. Coil Spring Removal

(1) Remove the coil spring from the magnetic switch.

Magnetic Switch
Coil Spring

E011768E

l. Magnetic Switch Disassembly

(1) Remove the screws that fix the cover, and then re-
move the cover and rubber cover.
< CAUTION >
• Do not reuse the rubber cover.

Screws
E011769E

-49-
 (2) Remove the plunger.

Plunger

E011770E

6-3. PARTS INSPECTION AND REPAIR

A. Armature Inspection
a. Coil Layer Short Inspection
(1) While contacting a piece of iron to the core in paral-
lel, use a growler tester to inspect the armature coil
for a layer short
< CAUTION > Thickness Gauge
• Before inspection, be sure to wipe away any foreign mat-
ter adhering to the armature surface.

The thickness gauge does not attract

Standard
or does not vibrate.
E009043E

b. Coil Insulation Inspection

(1) Using a 500V megger tester, measure resistance be-
tween the commutator and the armature core.

Standard Value 0.1MΩ or more.

Megger Tester EP2819E

-50-
c. Commutator Run-Out Inspection
(1) Support the armature with the two V blocks, and use
a dial gauge to measure the run-out.

Standard Value 0.05mm or less.

Level
Block

EP2821E

d. Commutator Outer Diameter Inspection

(1) Using vernier calipers, measure the outer diameter
of the commutator.

R1.0/1.6, RA1.2/1.4 30mm

Standard R2.0/2.2, RA1.8/2.0 35mm
Value R2.5/2.7/4.5 36mm
R3.0 43mm
R1.0/1.6, RA1.2/1.4 29mm or
less EP2822

R2.0/2.2, RA1.8/2.0 34mm or

Replacement less.
Standard R2.5/2.7/4.5 35mm or
less.
R3.0 42mm or
less.

e. Commutator Undercut Depth

(1) Install a needle probe on the dial gauge and mea-
sure the depth between the segment and the under- Probe
cut section. t

R1.0/1.6, RA1.2/1.4 0.6mm

Segment t: Undercut Depth
Standard Value R2.0/2.2/2.5/2.7/3.0/
0.8mm Level
4.5, RA1.8/2.0 Block

Replacement 0.2mm or less.

Standard EP2823E

-51-
B. Bearing Inspection
a. Inspection
(1) Check there is no abnormal noise or resistance
when the front bearing and rear bearing are rotated. Front Bearing
Replace if there is an abnormality.

E008873E

< CAUTION >

• The installation position of the bearings is different in the
R2.0/2.2 type starters.
Front Bearing

E011740E

b. Front Bearing Replacement

(1) Using a bearing puller, remove the front bearing.
< CAUTION >
• Do not reuse the front bearing.

Bearing Puller

E008874E

(2) Using a bench press, install a new front bearing.

< CAUTION > Press
• Press the inner side of the bearing as shown in the dia- Top
gram.

Pipe

Bottom E008875E

-52-
c. Rear Bearing Replacement
(1) Using a bearing puller, remove the rear bearing.
< CAUTION >
Rear Bearing
• Do not reuse the rear bearing.
Bearing
Puller

E008876E

(2) Using a bench press, install a new rear bearing.

< CAUTION > Bench Press
• Press the inner side of the bearing as shown in the
diagram.

Pipe
Rear
Bearing

Base
E008877E

C. Yoke Inspection
a. Type Without Shunt Coil
(1) Field coil continuity inspection: Using a multimeter,
check there is continuity between the field coil brush
and terminal C.
Multimeter
Standard Value 1Ω or less.

EP2825E

(2) Field coil insulation inspection: Using a 500V meg-

ger tester, measure resistance between the field coil
brush and the yoke.

Standard Value 0.1MΩ or more.

Megger Tester
EP2826E

-53-
b. Type With Shunt Coil
(1) Field coil continuity inspection: Using a multimeter
(as shown in the diagram), check there is continuity
Field Coil Continuity Inspection
between the field coil brush and the terminal C.
(Same as the conventional R type.)
< CAUTION >
Brush
• The conventional type field coil insulation inspection (ter-
minal C to body ground) cannot be performed because
the shunt coil is connected between terminal C and the
body ground.
Terminal C
Standard Value 1Ω or less.

E008880E

(2) Shunt coil continuity inspection: Using a multimeter,

check there is continuity between terminal (A) and
terminal (B). Replace the yoke if the measured value
is outside the standards.
Multimeter
Standard Value 1.5 - 1.9Ω
(A) (B)

E009028E

D. Brush Inspection
a. Measure the brush length at the center of the brush.

Replacement
Standard Value
Standard
R1.0, 1.2 13.0 11.3
R1.4, R1.6 15.0 11.0
R2.0 15.0 13.0
R2.2 16.5 13.0
R2.5, 2.7, 4.5 20.5 16.0 EP2827

R3.0, R5.5 21.0 17.0

2R1.4 15.0 11.0
RA1.2, 1.4 15.0 11.0
RA1.8, 2.0 15.0 12.0

< CAUTION >

• If the brush has worn beyond the limit, replace it according to the replacement procedures described in [5].

-54-
E. R Type Brush Replacement Procedures
a. Cutting the Brush Lead Wire
(1) Using nippers, cut the base (soldered end) of the
brush lead wires on the yoke side. Cut or file about Approx. 1mm

1mm as shown in the diagram.

Cut Cut
Brush Lead Wire

Nippers

EP2828E

b. Filing the Welded Parts

(1) File away the solder on the brush lead wire with nip-
pers and a file. Eliminate Burrs
< CAUTION >
• The filing area is small, so be careful not to damage the
field coil.

EP2829E

c. Brush Plate Pressing

(1) Overlay the spare brush plate on the soldered area
of the brush lead wire, and press it with pliers. Plate
Spare Brush

EP2830E

d. Soldering
(1) Solder the pressed area.
< CAUTION > Apply Solder
• Apply the solder quickly to prevent it flowing onto the Brush Lead Wire
brush lead wire.
• Assemble the brush holder, and secure the safety gap
between the brush holder and brush spring.

EP2831E

-55-
F. RA Type Brush Replacement Procedures
a. Spare Brush Shape

Brush

Brush Welded Part

Plate

E019975E

b. Brush Replacement Procedures

(1) Remove the old brush and file it to the dimensions
below.
Position the welded
Thickness 2.5mm part facing inwards.

Width 8.0mm

< CAUTION >

• Take care not to scratch the field coil when filing the re-
moved brush part.

(2) Wind the spare brush plate around the removed

Yoke
brush and press.
< CAUTION > Removed Brush Part
• Face the welded part of the spare brush towards the in-
side of the yoke. E019976E

(3) Solder the pressed area, and then file it until it meets
the standards shown in the diagram on the right.

6mm

12mm

E019977

-56-
G. Brush Spring Load Inspection
a. No rust or fatigue.

H. Brush Holder Insulation Inspection

a. Using a 500V megger tester, measure resistance between
the positive (+) side brush holder and the negative (-) side
brush holder.

Standard Value 0.1MΩ or more.

Megger Tester
EP2833E

I. Clutch
a. Check the gear is not worn or damaged. Check the direction in which the clutch idles. The clutch should only idle in one
direction. If there is an abnormality, replace the clutch. As a final check, use a test bench to perform a lock torque test
and then judge. However, first refer to [9] "Pinion Gear Replacement Method".

<When the Clutch Can Be Removed from the Housing>

E009044E

<When the Clutch Cannot Be Removed from the Housing>

E009029E

-57-
J. Pinion Gear Replacement Method
a. When the Clutch Can Be Removed from the Drive Housing
(1) Secure the SST in the vise as shown in the diagram,
and install the clutch. Then, turn the handle to push
Handle
the clutch shaft out, and push down the pinion stop Pinion Stop Collar
collar.

STT (DENSO Part

95028-10121
Number)

EP2944E

(2) Using snap ring pliers, remove the snap ring. Then
remove the stop collar and pinion gear from the Snap Ring
Pliers
clutch shaft. At this point, inspect the clutch shaft
Snap Ring
spline for damage, and check whether the clutch
shaft is bent. Replace the clutch shaft if abnormali-
ties are found during inspection.
< CAUTION >
• Do not reuse the snap ring.
EP2945E

b. When the Clutch Cannot Be Removed from the Drive Housing

(1) Secure the SST in the vise as shown in the diagram,
and set the clutch sub-assy on the STT.

STT (DENSO Part STT

95028-10121
Number)

EP2812

(2) Turn the handle as shown in the diagram, push the

clutch sub-assy shaft, and push the pinion stop collar Pinion Stop Handle
down. Collar

E011771E

-58-
 (3) Snap ring removal: Using snap ring pliers, remove
the snap ring. Remove the pinion from the clutch Snap Ring Pliers
shaft, and remove the clutch from the drive housing.
< CAUTION > Snap Ring
• Do not reuse the snap ring.

EP2814E

c. Pinion Gear Replacement and Assembly

(1) Replace the pinion gear and snap ring with the spare
parts, and assemble in the reverse order to the dis-
Pinion Gear Clutch Gear
assembly procedures.
Snap Ring
< CAUTION >
• Apply DENSO No. 50 grease to the clutch shaft.

Pinion Stop Clutch Shaft

Collar Snap Retainer
EP2946E

-59-
K. Magnetic Switch Inspection
a. Continuity Inspection
(1) Check continuity between terminal 50 and terminal
C.

Standard Value 1Ω or less.

Terminal C

E016878E
Terminal 50

(2) Check continuity between terminal 50 and the mag-

netic switch body. Magnetic
Switch Body
Standard Value 2Ω or less.

Terminal 50 E016879E

b. Contact Plate Inspection

(1) Wipe away any dirt on the contact surface of the con-
tact plate with a dry cloth, and inspect the contact
surface for roughness. If there is any roughness,
smooth with sandpaper (no. 300 or above). If the sur- Terminal C

face is extremely rough, replace the terminal kit parts

as a set.

Terminal M

Contact Plate E011772E

-60-
c. Terminal M Disassembly (Aluminum Frame Type)
*1: Terminal C is disassembled in the same way.
(1) Remove the terminal M nut, and then remove the
wave washer, outer bushing, packing, O-ring, insula-
Housing
tion paper, inner bushing, contact plate and bolt.
< CAUTION > Nut
• Do not reuse the terminal M part. Wave Washer
Outer Bushing
Packing
O-Ring

Insulating Paper

Inner Bushing
Contact Plate
Bolt E008882E

< CAUTION >

• Packing is not included in some terminal kits.
• Be sure to only use insulation paper with no insulation
coating on the terminal M assembly surface of the hous- Terminal 50
ing.
Insulating Coating

E011773E

-61-
d. Terminal M Assembly (Aluminum Frame Type)
*1: Terminal C is assembled in the same way.
(1) Replace all the terminal M kit parts as a set, and pre-
liminarily assemble them.
Housing
< CAUTION >
• Assemble so the depression in the wave washer faces
the nut.
• Assemble the inner bushing so that its long and short
sides are aligned with the long and short sides of the bolt Interior
head. O-Ring
• Make sure the O-ring and packing are not twisted, and
that they do not get pinched during assembly.
Bolt Inner Bushing

Short

Long E011774E

(2) Align the depression in the jig with the bolt head, and
insert and set. Base

Housing

Bolt Head

Jig E011775E

-62-
 (3) While applying 981N (100kgf) of force with the hand
press to secure the jig, use the torque wrench to
tighten the nut to the specified torque. Torque
Wrench
16.7N•m (13.7 - 19.6N•m)
Tightening Torque

M8 bolt
170kgf•cm (140 - 200kgf•cm)
32.4N•m (30.4 - 34.3N•m)
M10 bolt Jig
330kgf•cm (310 - 350kgf•cm)
Housing EP2936E

< CAUTION >

• After work is complete, there should be no interference between the bolt head and the contact. There should also be no
abnormalities in the inner or outer bushing.
• Always use the jig (STT) when performing this work. If the nut is tightened without using the jig, the bolt may rotate and
damage the bushing.
• Assembly Jig (STT)

For normal R and RA type starters.

For starters where the terminal M contact point is installed
(For M8, M10.)
For M8: 95028-10130 on pentagonal slanted areas etc. (For M8.)
Part Number Part Number: 95028-10140
For M10: 95028-10150 EP2937E

• Jig Assembly Example

EP2938

-63-
e. Terminal M Disassembly (Plastic Frame Type)
*1: Terminal C is disassembled in the same way.

<Terminal Construction Diagram>

Terminal Fixing Nut

Magnetic Switch Housing

Washer
Bolt
Terminal O-Ring

Terminal 50 Metal Collar O-Ring

Metal Collar
Contact Plate

Terminal C

Terminal M

Contact Plates
E008883E

(1) Secure the contact plate to the magnetic switch

housing with the press and a cylindrical rod of about
Cylindrical Rod
ϕ37, and remove the terminal fixing nut with the
ratchet wrench (14mm).

Magnet Switch Housing E014151E

< CAUTION >

• Always secure the contact plate to the magnetic switch
housing with the press when removing the terminal fixing
nut. This will prevent an excessive load being applied to Press
the plastic frame.

Plastic Frame
Cylindrical Rod
( 37)

Terminal
Terminal

Magnetic
Switch Housing Contact Plates

E000460E

-64-
 (2) Remove the washer, the bolt O-ring, the bolt, the
contact plate, and the metal collar O-ring.
Contact Plate
< NOTE >
• Using a sharp needle, lift up the edge of the metal collar
O-ring and remove the O-ring.

< CAUTION >

• Do not reuse removed washers, O-rings, and bolts.

Bolt

E014155E

f. Terminal M Kit Assembly (Plastic Frame Type)

*1: Terminal C is assembled in the same way.
(1) Set a new O-ring for the metal collar, and use a ded-
icated STT (part number: 95028-10160) to install it,
pushing the O-ring all the way to the back.

STT E014154

(2) Set a new contact plate and bolt to the plastic frame.

Contact Plate

Bolt

E014153E

-65-
 (3) Set a new O-ring for the bolt, and use a dedicated
STT to install, pushing the O-ring all the way to the
back.

STT (DENSO Part

95028-10160
Number)

STT O-Ring E014156E

< CAUTION >

• Firmly press down the face of the bolt with your finger
while press fitting the O-ring.

Metal Collar O-Ring

Bolt O-Ring
<STT for O-Ring Insertion>
E011778E

(4) Set a new washer to the bolt and preliminarily tighten

the nut.
Washer Nut

E014158E

(5) The other contact plate is installed according to the

same procedures. Nut Washer

E014159E

-66-
 (6) While pressing the two contact plates to the magnet-
ic switch housing with a press and a cylindrical rod of
Cylindrical
about ϕ37, tighten the terminal fixing nut to the spec- Rod
ified torque with the ratchet wrench (14mm).

Tightening 17N•m (14 - 20N•m)

Torque 174kgf•cm (144 - 204kgf•cm)

Magnet Switch
Housing

E014160E

< CAUTION >

• The contact plates are pressed down to prevent the con-
tact from moving up and down during tightening. The
pressing force should be about 981N {10kgf}. Press
• Clean any areas contacting the surface of the cylindrical
rod to remove any adhering substances (such as oil).
Plastic Frame
Cylindrical Rod
( 37)

Terminal
Terminal

Magnetic
Switch Housing Contact Plates

E000460E

g. Plunger Inspection
(1) Wipe off any dirt from the contact surface of the
plunger with a dry cloth, and inspect the contact sur-
face for roughness. If there is any roughness,
smooth with sandpaper (no. 300 or above). If the sur-
face is extremely rough, replace the plunger.

Plunger

Contact Surface EP2939E

-67-
6-4. Magnetic Switch Operation Inspection
< CAUTION >
• Perform each test in a short period of time (3 to 5 seconds).

A. Pulling-In Test
a. Remove the nut and the lead wire from terminal C.
b. With connections as shown in the diagram

Battery Terminal 50 Terminal C

Battery Body and Terminal C

Pinion gear springs out.

< CAUTION > Terminal 50

• Always remove the terminal C lead wire when performing
the test.
EP2835E

B. Holding Test
a. From the pull-in test conditions, check the pinion remains
out even after the test wire is disconnected from terminal
C. Remove the ground wire, and verify that the pinion gear Terminal C
returns.

Terminal
50 Disconnect

EP2836E

C. Return Test
a. With connections as shown in the diagram

Battery Terminal C Terminal C

Battery Body and Terminal 50

Pinion gear springs out.

If terminal 50 is removed during this state, Dis-

connect
the magnetomotive forces of both coils
will balance out. Terminal 50

The pinion gear will instantly return. EP2837E

-68-
6-5. ASSEMBLY PROCEDURES
Assembly is basically carried out in the reverse order to disassembly. However, the required inspections and checks must
be repeated properly to ensure all procedures are fulfilled and prevent mistakes in the assembly order, which will cause
malfunctions.

A. Cautions for Assembly

a. Applying Grease
(1) Apply DENSO No. 50 grease to the areas shown below.

Coat with DENSO No. 50 grease.

Coat with DENSO No. 50 grease.

Coat with DENSO No. 50 grease.

Coat with DENSO No. 50 grease. <Reading Tightening Torque Values>

E.g
1.4 (1.1-1.7) 1.4N·m (1.1-1.7N·m) SI Unit
15 (12-18) 15kgf·cm (12-18kgf·cm) “kgf·cm” Unit

<Tightening Torque List> Target Value Minimum - Maximum

Model R1.0/1.6 R2.0/2.2 R2.5/2.7/4.5 R3.0 RA1.2/1.4 RA1.8/2.0

Through-Bolts 9.3 (6.9-11.8) 12.7 (10.8-14.7) 9.3 (6.9-11.8) 14.2 (10.7-17.7) 5.9 (4.4-7.4) 10.3 (8.8-11.8)
(Motor) 95 (70-120) 130 (110-150) 95 (70-120) 145 (110-180) 60 (45-75) 105 (90-120)
Housing 9.3 (6.9-11.8) 9.3 (6.9-11.8) 9.3 (6.9-11.8) 9.3 (6.9-11.8) 5.9 (4.4-7.4) 10.3 (8.8-11.8)
Bolts 95 (70-120) 95 (70-120) 95 (70-120) 95 (70-120) 60 (45-75) 105 (90-120)
End Frame 1.5 (1.2-1.8) 3.6 (2.6-4.6) 3.6 (2.6-4.6) 1.5 (1.2-1.8) 3.8 (2.9-4.7)
Screws 15 (12-18) 37 (27-47) 37 (27-47) 15 (12-18) 39 (30-48)
M10 21.1 (17.6-24.5)
Terminal C 16.6 (13.7-19.6) 16.6 (13.7-19.6) 30 (25-35) 215 (180-250) 16.6 (13.7-19.6) 11.8 (9.8-13.7)
Nuts (Inner) 170 (140-200) 170 (140-200) 305 (250-360) M12 26.0 (22.5-29.5) 170 (140-200) 120 (100-140)
265 (230-300)
Terminal C 5.9 (4.4-7.4) 5.9 (4.4-7.4) 24 (20-28) 24 (20-28) 5.9 (4.4-7.4) 5.9 (4.4-7.4)
Nuts (Outer) 60 (45-75) 60 (45-75) 245 (205-285) 245 (205-285) 60 (45-75) 60 (45-75)
M10 21.1 (17.6-24.5)
Terminal M 16.6 (13.7-19.6) 16.6 (13.7-19.6) 30 (25-35) 215 (180-250) 16.6 (13.7-19.6) 16.6 (13.7-19.6)
Nuts 170 (140-200) 170 (140-200) 305 (250-360) M12 26.0 (22.5-29.5) 170 (140-200) 170 (140-200)
265 (230-300)
Mg/sw 3.6 (2.6-4.6) 3.6 (2.6-4.6) 3.6 (2.6-4.6) 3.6 (2.6-4.6) *2.5 (1.8-3.2) *4.1 (3.6-4.6)
Cover Bolts 37 (27-47) 37 (27-47) 37 (27-47) 37 (27-47) 25 (18-32) 42 (37-47)
* Depending on the starter, the following tightening torques may also be appropriate.
4.9N·m (3.4 - 6.4N·m)
50kgf·cm (35 - 65kgf·cm) E008998E

-69-
b. Magnetic Switch and Clutch Assembly
(1) Assemble the clutch to the magnetic switch and in-
stall the idle gear. Then assemble the drive housing.
Steel Ball
< CAUTION >
• Be sure to assemble the steel ball to the clutch.
• Be sure to assemble the retainer and roller to the idle Retainer
gear.

Idle Gear E011779E

c. Assemble the armature to the yoke.

d. Brush Assembly
(1) Lift the brush spring and assemble the four brushes
to the brush holder as shown in the diagram. Side Brush
Insulator
Brush Spring Side Brush

Side Brush Holder Hole

Side Brush Holder Hole EP2840E

e. End Frame Assembly

(1) Assemble a new O-ring to the yoke.
(2) When assembling the end frame to the yoke, align
the notch in the end frame with the lead wire
Notch
grommet.

Lead Wire
Grommet

O-Ring E011780E

-70-
f. Yoke Assembly
(1) Install a new O-ring to the yoke.
(2) When assembling the yoke to the magnetic switch,
align the notch in the yoke with the magnetic switch O-Ring

protrusion. Notch

Protrusion

E011781E

g. Other (Terminal 50 Rubber Check)

(1) Check the terminal 50 rubber has not detached or
deviated.
< CAUTION >
• If the rubber has detached, insert it properly. Rubber for
Terminal 50

Terminal 50

E008885E

6-6. PERFORMANCE TEST

For the performance test, refer to section "PINION SHIFT TYPE (GA TYPE) STARTER". (Reference: "PERFORMANCE
TEST" on page 34.)

6-7. TROUBLESHOOTING
For troubleshooting, refer to section "PINION SHIFT TYPE (GA TYPE) STARTER". (Reference: "TROUBLESHOOT-
ING", page 38.)

-71-
7. PLANETARY TYPE (P TYPE) STARTER
7-1. CONSTRUCTION AND OPERATION
• The planetary type starter is a reduction type starter that uses a planetary gear. It uses the same type of compact, high-
speed motor as the reduction type, and has a planetary gear between the clutch and armature. This has enabled a more
compact and lightweight starter design.
• To engage with the engine, the magnetic switch moves the clutch forward, via the drive lever. The clutch slides along a
shaft (planet carrier shaft) connected to the planetary gear.

Magnetic Switch

Armature

Field Coil

Drive Lever

Clutch

Planetary Gear

Internal Gear

Pinion Gear Sun Gear

E008886E

-72-
A. Planetary Gear Type Deceleration Mechanism
• The planetary gear type deceleration mechanism consists
of three planetary gears engaged with a sun gear, and an
Planet Carrier
internal gear that surrounds the planetary gears. Planetary Gear Clutch
Armature

Pinion Gear

Sun Gear
Internal Gear
Armature Shaft E008887E

• The sun gear is connected to the armature shaft, so when

the armature rotates, the sun gear rotates the planetary
gears in the reverse direction. The internal gear is fixed, so Planetary Gear
the planetary gears orbit the sun gear in the same direction
as the sun gear rotates.
• The planetary gear axes are connected to the planet carri-
er, so the planet carrier shaft also revolves when the plan-
etary gears orbit.
• In this planetary gear type, the planet carrier shaft rotates
once for every five rotations of the sun gear (i.e. the arma-
Internal Gear
ture). This is a deceleration of 1/5. Sun Gear E08888E

Planet Carrier Shaft Internal Gear (Fixed)

Armature Shaft

Sun Gear

Planetary Gear

Pinion Gear
Planet Carrier E008889E

-73-
B. Shock Absorber (Shock Absorber Bearing)
The internal gear is normally fixed. However, if excessive
torque is applied, the internal gear gives way and is rotated Sun Gear Internal Gear
by the excess torque.

Planet Carrier
Shaft
Planetary Gear

Clutch Plate Shock Absorber Bearing

E008890E

a. Shock Absorber Construction

The tab on clutch plate 1 engages the internal gear, and clutch plate 2 is secured to clutch plate 1 with fixed pressure
from the spring washer and nut.

Center Bearing Case

Tab Connection
Tab Spring Washer

Clutch Plate 1

Wave Washer Clutch Plate 2 Internal Gear

Shock Absorber E008971E

b. Shock Absorber Operation

The internal gear engages with clutch plate 1 in the shock
absorber bearing. In addition to securing the internal gear,
Internal Gear
clutch plate 1 rotates if a high torque is applied to the inter-
nal gear. This means it absorbs some of the rotating torque
Spring
from the planet carrier shaft. Thus the torque applied to the Washer
sun gear and internal gear is kept below a certain value.

Clutch Plate

Shock Absorber Bearing

E008972E

-74-
8 PLANETARY TYPE (P TYPE) STARTER REPAIR

8-1. Introduction
A. Cautions for Work
a. Work Environment
(1) Clear and clean the work stand before beginning work.
(2) Do not perform work in humid, dirty or dusty places.
b. Cautions for Disassembly and Reassembly
(1) Regularly tidy the work area to prevent loss of parts.
(2) Do not secure high-precision parts tightly in a vise, or hit them with a hammer.
(3) When installing bolts and nuts, use a torque wrench and torque driver to tighten them to the values shown in the test
standards table.

B. Preparatory Items List (Not Including General Tools)

< CAUTION >
• Refer to the "Pinion Shift Type (GA Type) Starter Repair Preparatory Items List" on page 14 for information on STT and
tools not listed below.

DENSO Part
Classification Part Name Remarks
Number

Center Bearing Press Fitting 95028-10090

Tool

E014166

Attachment Measure 95028-10100 For the shock

absorber torque
wrench.
STT

E014167

Holder Plate 95028-10110 For the shock

absorber torque
wrench.

E014168

Micrometer - For measuring the

outer diameter of
the planet carrier
EP2898 shaft.

Caliper Gauge - For measuring the

inner diameter of
Tool the center bearing.
E014169

Tap - For oilless bearing

removal.

E014170

-75-
8-2. DISASSEMBLY

Bearing

Center Bearing Sub-Assy

Washer
Magnetic Switch

Planet Carrier Shaft

Pinion Gear
Drive Housing

Internal Gear

Oilless Bearing
Drive Lever
Washer
Snap Ring End Frame
Clutch

Stop Collar
Through-Bolt
Screw
Snap Ring

Needle Bearing

Oilless Bearing
Yoke

Brush Holder

Planetary Gear
Armature

O-Ring

O-Ring
Plate

Washer

E008973E

-76-
A. Magnetic Switch Removal
a. Disconnect the lead wire and remove the two installation
nuts. Magnetic Switch
b. Remove the stud bolt from the drive lever while lifting up
the front of the magnetic switch, and then remove the Installation Lead Wires
magnetic switch. Nuts (2)

EP2868E

B. Yoke Removal
a. Remove the two through-bolts, and then remove the yoke.
Through-Bolts

Yoke

End Frame
EP2869E

C. End Frame Removal

a. Remove the two screws shown in the diagram, and then
remove the end frame Yoke
< CAUTION > End Frame
• The brush holder and water bleed pipe will interfere
internally, so tilt the end frame to remove it.
• Press the lead wire to the yoke side so it does not get
pulled when removing the end frame. Lead Wires

Water Bleed
Screws Pipe
E008974E

D. Brush Holder Removal

a. Using a screwdriver, lift up the brush spring and remove the brush.
b. Remove the brush holder from the yoke.

Brush Spring

Yoke
EP2871E

-77-
E. Armature Removal
a. Remove the armature from the yoke.
Armature

Yoke

End Frame EP2872E

F. Clutch Removal
a. Remove the clutch and drive lever from the drive housing.

Drive Lever

Clutch

Drive Housing

E008975E

G. Planetary Gear Removal

a. Remove the plate, and then remove the three planetary
gears. Clutch
Washer
Planetary Gear
Plate

E008976E

H. Snap Ring Removal

a. Remove the snap ring and stop collar, and separate the
clutch.
Snap Ring Pliers
Press Snap Ring
Jig

Stop Collar
Clutch

E008977E

-78-
I. Planet Carrier Shaft Removal
a. Remove the snap ring and disassemble the center bearing
and the planet carrier shaft.
Planet Carrier Shaft

Center Bearing Sub-Assy

Snap Ring

E009030E

J. Internal Gear Removal

a. Align the depression on the exterior of the internal gear
with the protrusion in the interior of the center bearing, and
remove the internal gear.

Internal Gear

Indent Center Bearing

Sub-Assy
Protrusion E008878E

8-3. Inspection
< CAUTION >
• The standard values and replacement standards differ according to the starter, so refer to the individual test standards.

A. Armature Inspection
a. Layer Test
(1) Using a growler tester, inspect the armature coil for
a layer short.
Thickness Gauge
The thickness gauge does not attract
Standard Armature
or does not vibrate.

< CAUTION > Growler

Tester
• Remove particles such as carbon grains from around the
commutator before inspection.

EP2878E

-79-
b. Insulation Test
(1) Using a 500V megger tester, measure resistance be-
tween the commutator and the armature core. Armature Core
Commutator
Standard Value 0.1MΩ or more.
M

Megger Tester
EP2879E

c. Commutator Run-Out Inspection

(1) Use a dial gauge to inspect. Replace if the run-out
(the difference between the maximum diameter and
Dial Gauge
minimum diameter) is more than 0.05mm.
V Blocks
Standard Value 0.02mm

Replacement Standard 0.05mm

Commutator EP2880E

(2) Using vernier calipers, measure the outer diameter

of the commutator.

Standard Value 28.0mm

Replacement Standard 27.0mm

EP2881

d. Commutator Undercut
(1) Measure the depth below the segment surface: If in-
sulation material between the segments is higher NG
than the segment surface, it will prevent rectification. NG OK

Standard Value 0.6mm

Replacement Standard 0.2mm or less. t

Segments
Mica t: Undercut Depth
Replace when 0.2 mm or less.
EP2882E

-80-
B. Yoke Inspection
a. Field Coil Inspection
(1) Check continuity between the brush and the terminal
C lead wire.
Multimeter
< CAUTION > Terminal C
• Check both brushes for continuity. Lead Wire

Standard Value 1Ω or less.

E009032E

(2) Using a 500V megger tester, inspect resistance be-

tween the brush and the yoke body.

Standard Value 0.1MΩ or more.

Megger Tester
Yoke Body
E009033E

b. Brush Inspection
(1) If the brush length is shorter than the use limit of
9mm, or if there is significant damage on the contact
area with the commutator, replace with a new brush.

Standard Value 14mm

14 mm
Replacement Standard 11.1mm 11.1 mm

EP2886

-81-
c. Brush Replacement Procedures
(1) Cut the brush lead wire on the terminal side.
< CAUTION >
• In a P type starter, only the two brushes on the yoke side Brush
(+ side) can be replaced. The negative (-) side brush can
only be replaced as a unit with the brush holder.
Cut

Yoke Terminal

E011782E

(2) Grind the solder on the brush terminal with a file so

that the terminal meets the standard dimensions.

AB Cross-Section
A B
Cut

Yoke Side
Terminal
C Yoke Side
C Terminal
EP2888E

< CAUTION >

• Grind area C of the brush terminal as shown in the
diagram. The grinding area is small, so be careful not to
damage the field coil.
Width Thickness
Brush Terminal Standard Dimensions
Thickness 1.6mm
Width 5.0mm

EP2889E

(3) Overlay the spare brush plate on the soldered side

of the lead wire, and press it with pliers.
< CAUTION >
• Do not mistake the layout direction of the brush lead wire.
Lead Wire Welded Side

EP2890E

-82-
 (4) Solder the pressed area, and then file with a file until
it meets the standards as shown in the diagram.

3.3mm or less (thick-

Standard ness). 3.3 mm

7mm or less (width).

< CAUTION >

7 mm
• Apply sufficient heat to the area to be soldered, and do
not solder the positive side of the lead wire.
• Apply sufficient solder to the inner side of the plate. EP2891

• Make sure solder does not drip towards the field.

d. Brush Spring Load Inspection

(1) Using a spring balance, read the dial (spring tension)
at the instant the spring separates from the brush.

Standard Value 13.72 - 17.65N (1.4 - 1.8kg)

Replacement 9N (0.9kg)
Standard Brush Spring

Brush
EP2892E

C. Brush Holder Inspection

a. Using a 500V megger tester, inspect insulation between
the positive (+) side and negative (-) side brush holders.
Side
Standard Value 0.1MΩ or more.

Side
Megger Tester
EP2893E

D. Clutch Inspection
a. Check the pinion gear locks when it is rotated counter
clockwise, and turns smoothly when rotated clockwise.
< CAUTION >
• Also check there is no pinion gear wear, damage, resis-
tance or rust, and that the gear rotates smoothly. Lock

Free

EP2894E

-83-
E. Magnetic Switch Inspection
a. Return Spring Inspection
(1) Check that the plunger quickly returns to its original
position when it is pushed down and released.

EP2895

b. Continuity Inspection
(1) Check continuity between terminal 50 and terminal
C.
Terminal C

Standard Value 1Ω or less.

Terminal 50

Multimeter EP2896E

(2) Check continuity between terminal 50 and the mag-

netic switch body.
Terminal 50
Standard Value 2Ω or less.

Magnetic Switch
Body

Multimeter
E009034

F. Front Bearing Inspection

a. Front Bearing Inspection Procedures
(1) Visually inspect the front bearing to make sure there
is no damage or rust. Drive Housing
(2) Check the front bearing rotates smoothly when the
shaft is inserted in the front bearing and rotated.
Replace the front bearing if there is an abnormality. Shaft

E009035E

-84-
b. Replacement Procedure
(1) Apply a cylindrical rod to the front bearing, and re-
move the front bearing with a rack press.
Rack Press

Drive Housing Cylindrical Rod

( 13mm)

E009036E

(2) Press fit the front bearing with a rack press.

< CAUTION >
• When necessary, press fit the front bearing with the plate

A
inserted to secure dimension A.

Dimension A 0 - 0.4mm

E009037

G. Center Bearing Inspection

a. Center Bearing Oil Clearance Inspection
(1) Using a micrometer, measure the outer diameter of
the planet carrier shaft.

Standard Value 14.99mm (example).

EP2898

(2) Using a caliper gauge, measure the inner diameter

of the center bearing.

Standard Value 15.03mm (example).

(3) Calculate the oil clearance from the outer diameter of

the planet carrier shaft and the inner diameter of the
center bearing.

Standard Value 0.04mm (example).

EP2899

Replacement Standard 0.2mm or more.

< CAUTION >

• If the limit is exceeded, replace the center bearing or the planet carrier shaft.

-85-
b. Oilless Bearing Replacement
(1) Using the STT and a hand press, remove the oilless
bearing.

STT (DENSO Part

95028-10090
Number)
STT
< CAUTION >
• When removing the oilless bearing, be sure to remove it
from the inside as shown in the diagram.

EP2901

(2) Using an STT, install a new oilless bearing with a

hand press. Hand Press

STT (DENSO Part

95028-10090
Number)
STT

EP2900E

< CAUTION >

• When hammering the oilless bearing, make sure it does
not protrude from the end of the center bearing sub-assy
surface. No Protrusion
Center Bearing
Sub-Assy

0.5 mm
or less.
Oilless
Bearing

E008978E

-86-
H. End Frame Oil Clearance Inspection
a. End Frame Oil Clearance Inspection
(1) Measure the outer diameter of the armature shaft at
the end frame sliding part and the inner diameter "b"
of the end frame, and calculate the clearance. If the a
replacement standard is exceeded, replace either
part. b Armature
Shaft
a - b: 0.035mm (exam-
Standard Value
ple). End Frame
Replacement Standard a - b: 0.10mm.

a. Armature Shaft 7.0mm

Standard Value
b. End Frame 7.035mm EP2903E

b. Oilless Bearing Replacement

(1) Using the tap as shown in the diagram, remove the
oilless bearing.
< CAUTION >
• Do not deform or damage the end frame when securing
the end frame in the vise.

Tap

Oilless Bearing
E009038E

(2) Press fit a new oilless bearing as shown in the dia-

gram, and then install.

Oilless Bearing

Standard Dimension After

Press Fitting:
22.04-22.36mm EP2905E

I. Shock Absorber (Shock Absorber Bearing) Inspection

a. Securing the Drive Housing
(1) Secure the drive housing flange in the vise, and as-
semble the center bearing so that both markers are Center Bearing Sub-Assy
Drive Housing
aligned as shown in the diagram.
< CAUTION >
• Do not tighten the vise excessively when securing the
drive housing. Tightening is sufficient if the housing does Vise
not move.
• Assemble the shock absorber bearing and check that it
does not rotate.
Protrusion Indent Marker
Marker E008981E

-87-
 (2) Assemble the STT as shown in the diagram, rotate
slightly, and fit into the shock absorber. STT Tool

STT (DENSO Part

95028-10100
Number)

Center Bearing
E008982E

(3) Secure the STT from the top of the shock absorber
bearing to the through-bolt fixing area of the drive STT
housing, as shown in the diagram.

STT (DENSO Part Through-Bolt

95028-10110 Fixing Area
Number)

EP2908E

(4) As shown in the diagram, apply torque with the

torque wrench through STT 95028-10100, and read
Torque Wrench
the sliding torque value when rotation starts. It may
rotate in either direction. If the value is over the limit,
replace the entire shock absorber bearing.

29.42N•m (25.5 - 33.34N•m)

Standard Value STT Tool
300kgf•cm (260 - 340kgf•cm)

Replacement
21.57N•m (220kgf•cm) EP2909E
Standard

< CAUTION >

• Never disassemble or clean the shock absorber. Do not reuse if cleaned or disassembled.

J. Planet Bushing Clearance Inspection

a. Calculate the clearance from diameter "b" of the planet pin
press fit to the planet carrier shaft, and inner diameter "a"
Planet Carrier Shaft Planetary Gear
of the planet bushing. If the replacement standard is ex-
ceeded, replace the planetary gear or the planet carrier
shaft. Planet Bushing
b
Standard Value 0.03mm (example). a

Replacement Standard 0.10mm

Planet Pin
EP2910E

-88-
8-4. ASSEMBLY
A. Internal Gear Installation
a. Apply 2g or more of No. 50 grease to the internal gear,
shock absorber connection and interior of the internal gear DENSO No. 50 Grease
as shown in the diagram. Then align the markers and as-
semble.

Internal
Gear
Markers EP2911E

B. Planet Carrier Shaft Installation

a. Coat the interior of the shock absorber bearing with tur-
bine oil (type 2 no. 83). Apply No. 50 grease to both sides DENSO No. 50 Grease
of the washer, and after installing the planet carrier shaft,
assemble the shock absorber bearing.

Planet Carrier
Shaft
Plate Washer

Turbine Oil Type 2 No. 83 EP2912E

C. Snap Ring Installation

a. Install a new snap ring to the planet carrier shaft.
< CAUTION >
• The old part cannot be reused.
• Check that the washer has been installed.

Snap Ring

Washer
EP2913E

D. Clutch Assembly
a. Apply No. 50 grease to the clutch and spline contact parts,
the stop collar and the snap ring, and then assemble. Snap Ring

Stop Collar

No. 50 Grease EP2914E

-89-
b. Holding the exterior of the clutch in your hand, use a plas-
tic hammer to lightly tap the planet carrier shaft, moving
the stop collar and securing it on the snap ring.

EP2915

E. Planetary Gear Installation

a. Apply at least 0.5g of No. 50 grease to the three planetary
gears, and then install them and the washer. DENSO No. 50 Grease
< CAUTION > Plate Washer
• Align the markers on the plate and the center bearing
sub-assy when installing the plate.

Markers

Planetary Gears
EP2916E

F. Drive Lever and Housing Installation

a. Coat the drive lever and clutch contact surfaces with
DENSO no. 50 grease.
b. Assemble the drive lever to the clutch. DENSO No. 50
Grease

Drive
Lever Drive
Clutch Housing
E011783E

G. Shock Absorber Installation

a. Assemble the drive housing and shock absorber bearing
so the alignment marks are aligned. Center Bearing Alignment
Sub-Assy Marks

Drive Housing E008983E

-90-
H. Brush Holder Installation
a. Install the brushes in the brush holder. Pull the brush
springs out and set the brush holder on the armature com-
Armature
mutator. Commutator

Brush

Hanger Brush
Spring

EP2919E

< CAUTION >

• Always check that the brush lead wire and the brush
spring are not contacting.

Brush Spring

Lead Wires EP2920E

I. End Frame Installation

a. Replace the O-ring with a new part, and install the commu-
tator end frame.

Tightening 1.4 (1.1 - 1.8) N•m

Torque 16 (12-18) kgf•cm

< CAUTION >

• To ensure the brush holder and water bleed pipe do not
interfere internally, tilt the end frame to install.
O-Ring
• Check the O-ring is assembled to the yoke.
E008984E

J. Yoke Installation
a. Align the depressions in the yoke with the plate and center
bearing sub-assy protrusions, and then install.
< CAUTION >
• Check the O-ring is assembled to the yoke.

Alignment Marks EP2922E

-91-
b. Install the two through-bolts

Tightening 5.9 (4.4 - 7.4) N•m

Torque 60 (45-75) kgf•cm

E009039

K. Magnetic Switch Installation

a. Hang the magnetic switch stud bolt from the upper side of
the drive lever, and install it with the two nuts.

Tightening 8.4 (5.8 - 10.8) N•m

Torque 85 (60-110) kgf•cm

EP2923

b. Install the lead wire to terminal C with the nut.

Tightening 9.8 (7.8 - 11.8) N•m

Torque 100 (80-120) kgf•cm

E009040

-92-
8-5. Magnetic Switch Operation Inspection
< CAUTION >
• Perform each test in a short period of time (3 to 5 seconds).

A. Pulling-In Test
a. Remove the nut and disconnect the lead wire from terminal C.
b. With connections as shown in the diagram
Disconnect from terminal C.
Battery Terminal 50
<Current Flow>
Battery Body and Terminal C Terminal C
Battery
Terminal 50
Pinion gear springs out.
H.C. P.C
Terminal C

Ground Terminal 50

E011741E

B. Holding Test
a. From the pulling-in test conditions, remove the lead wire from terminal C as shown in the diagram. Check the pinion re-
mains out.
b. Remove the ground wire, and check that the pinion gear
returns. Test Wire
<Current Flow>
Terminal C
Battery

Terminal 50

H.C

Ground
Terminal 50
E014171E

C. Return Test
a. With connections as shown in the diagram

Battery Terminal C <Current Flow> Terminal C

Battery Body and Terminal 50 Battery

Terminal C
Pinion gear springs out.

If terminal 50 is removed during this state, P.C

the magnetomotive forces of both coils
will balance out. Terminal 50
H.C Terminal 50
Ground
The pinion gear will instantly return. E011743E

8-6. PERFORMANCE TEST

For the performance test, refer to section "PINION SHIFT (GA TYPE) STARTER". (Reference: "PERFORMANCE TEST"
on page 34.)

8-7. TROUBLESHOOTING
For troubleshooting, refer to section "PINION SHIFT (GA TYPE) STARTER". (Reference: "TROUBLESHOOTING", page 38.)

-93-
9. PLANETARY SEGMENT TYPE (PS TYPE) STARTER
9-1. CONSTRUCTION AND OPERATION
• The PS (planetary reduction - segment conductor motor) starter uses uncoated, angular conductor armature coils to pro-
duce a highly efficient, compact and lightweight starter. The yoke uses a ferrite magnet instead of the conventional field
coil, which simplifies construction.

Magnetic Switch
End Frame

Drive Housing
Armature

Pinion Gear

Planetary Gear

Motor
Planet Carrier Shaft

<Cantilever Type PS Starter>

E009041E

A. Yoke (Magnetic Field Area)

• A ferrite magnet is used instead of the conventional field
coil, simplifying construction.
Inter-Pole
• In addition, inter-pole magnets are installed between the Magnets
main magnetic poles of the ferrite magnet. This improves
the electromagnetic circuit and increases the amount of
magnetic flux. It can produce the same amount of magnetic
flux as the conventional P type starter, with a more com-
pact design and a reduced motor axis length.

Main Magnetic Poles

Inter-Pole Magnetic
Magnets Flux of Main
Magnetic Poles
N S N S

S N
S N

N S

Magnetic Flux of
Inter-Pole Magnets E008985E

-94-
B. Armature
The armature coil uses uncoated, angular wires instead of
the conventional coated electric wires, increasing both coil
density and torque. The conventional cylindrical commuta-
tor has also been eliminated. Instead, the end of the arma-
ture is used as a commutator, reducing the armature axis
length.

Commutator E008986E

Conventional Starter
Cylindrical Commutator

Conventional Starter PS Starter

(Coated Electrical Wires) (Uncoated Angular Wires)
PS Starter
Brush Armature Coil Cross-Section

Armature Axis
Length Reduction

Brush E008987E

C. Brush Holder
Two brushes are installed on the brush holder, one on the
positive side and one on the negative side.

E008988

-95-
D. Planetary Gear Type Deceleration Mechanism
• The deceleration mechanism is basically the same as the one in the P type starter. The planetary gear type deceleration
mechanism consists of three planetary gears engaged with a sun gear, and an internal gear that surrounds the planetary
gears.

Planetary Gear

Internal Gear
Sun Gear
(Attached to Armature)

<Planetary Gear Construction 1> <Planetary Gear Construction 2>

E008989E

• The sun gear is assembled to the armature shaft, so when the armature rotates, the sun gear rotates the planetary gears
in the reverse direction. The internal gear is fixed, so the planetary gears orbit the sun gear in the same direction as the
sun gear rotates.
• The planetary gear axes are secured to the planet carrier, so the planet carrier shaft also revolves when the planetary
gears orbit.
• In this planetary gear type, the pinion gear rotates once for every 7.9 rotations of the sun gear (i.e. the armature). This
is a deceleration of 1/7.9.

Planet Carrier Shaft Internal Gear (Fixed)

Armature Shaft

Sun Gear

Planetary Gear

Pinion Gear Planet Carrier

Normal Planetary Deceleration Mechanism E008991E

-96-
E. Clutch
• Construction of the clutch is basically the same as in the P
type starter. There are two types of clutch depending on
Clutch
the shape and the pinion gear position: a center impeller
type and a cantilever type.
• The main parts are the inner (integrated with the drive
shaft), outer, roller, and spring.
• One end of the space that stores the roller is narrower than
the other. The clutch roller is kept pushed against the nar-
row end by the spring force.

Outer
* The photograph shows a cantilever type. E008992E

a. Starter Driving
When armature rotation is transmitted through the spline
tube to the outer, the outer rotates in the direction of the Roller
arrow. The spring force presses the roller into the narrow
end of the space between the outer and the inner. This Inner
Integrated with
locks the outer and inner together. The roller acts like a
Drive Shaft
wedge between the inner and outer, and transmits outer Outer
rotation to the inner, making both parts rotate at the same
speed.
b. After Engine Start-Up
(Outer and Inner are Locked)

When the ring gear rotates the pinion gear, the inner ro-
tation becomes faster than the outer rotation (armature Roller
rotation), which causes the roller to move in a direction to
compress the spring. Thus, the inner and outer become
free, preventing armature overrun. Inner

Outer

(Outer and Inner are Free)

-97-
F. Clutch Types

<Cantilever Type PS Starter> <Center Impeller Type PS Starter>

Clutch Clutch
Front Bearing
Front Bearing

Pinion Gear
Pinion Gear
E008993E

-98-
10 PS TYPE STARTER REPAIRS

10-1. INTRODUCTION
A. Cautions for Work
a. Work Environment
(1) The PS starter uses a strong permanent magnet, so make sure there is no metal (screws, washers, staples etc.)
around the work stand.
(2) Clear and clean the work stand before beginning work.
(3) Do not perform work in humid, dirty or dusty places.
b. Cautions for Disassembly
(1) Regularly tidy the work area to prevent loss of parts.
(2) Do not secure high-precision parts tightly in a vise, or hit them with a hammer.
(3) When installing bolts and nuts, use a torque wrench and torque driver to tighten them to the values shown in the test
standards table.

B. List of Preparatory Items (Not Including General Tools)

< CAUTION >
• For STT and tools not included below, refer to the item on GA type starter repairs.

DENSO Part
Classification Part Name Remarks
Number

Attachment Measure 95028-10170 For the shock

absorber torque
wrench.

E000846

HL50 Grease 028770-0040

SST

Turquoise
E000472E

Micrometer - For measuring

the outer diame-
ter of the planet
carrier shaft.
EP2898

Tool
Caliper Gauge - For measuring
the inner diame-
ter of the center
bearing.
E014169

-99-
10-2. DISASSEMBLY
A. Magnetic Switch Removal
a. Remove the terminal C nut with the socket wrench, and re-
move the lead wire from the terminal. Magnetic Switch

Terminal C Nut

EZ9068E

b. Remove the two bolts with a screwdriver.

< CAUTION >
• The magnetic switch will be pushed out by the internal Bolts
spring when the bolt is removed, so be careful it does not
fall.

EZ9069E

c. Remove the magnetic switch, plunger and spring from the

housing. Plunger Spring Magnetic Switch

EZ9070E

-100-
B. End Frame Removal
a. Remove the two through-bolts with a socket wrench.
End Frame
End Frame Cover

Yoke Through-Bolt EZ9071E

b. Remove the end frame (attached to the armature) from the

yoke.

Yoke Armature

End Frame E000866E

c. Remove the end frame cover.

End Frame Cover

E000867E

-101-
d. Remove the snap ring with the snap ring pliers.
< CAUTION > Snap Ring Pliers
• Do not reuse the snap ring.

EZ9072E

e. Remove the space ring.

f. Remove the end frame from the armature.

Snap Ring

Space Ring

E005591E

C. Yoke and Armature Plate Removal

a. Remove the yoke from the drive housing.
< CAUTION >
• Store the removed yoke in a place where there are no Yoke
metal objects.
• Do not disassemble the yoke.

EZ9077E

b. Remove the armature plate from the yoke.

Armature Plate

EZ9079E

-102-
D. Planetary Gear and Rubber Seal Removal
a. Remove the rubber sea
b. Remove the planetary gears.
Rubber Seal
< CAUTION >
• Be careful not to get dirt on the parts.

Planetary Gear
E007119E

E. Pinion, Clutch & Bearing, and Drive Lever Removal (Only for Cantilever Type PS Starter)
a. Remove the snap ring with the snap ring pliers.
< CAUTION > Snap Ring
Snap Ring Pliers
• Do not reuse the snap ring.

Clutch Tip

EZ9081E

b. Remove the pinion gear from the end of the clutch.

c. Remove the spring. Pinion Gear

Spring

E000868E

-103-
d. Remove the clutch & bearing and the drive lever from the
housing.
Clutch
& Bearing

Drive Lever

EZ9082E

< CAUTION >

• Do not remove the oil seal.
Oil Seal

EZ9083E

F. Clutch & Shock Absorber Bearing Disassembly

a. Cantilever Type PS Starter
(1) Place a screwdriver in the E-ring (in the position
shown in the diagram below), and lightly tap the
E Ring
screwdriver with a hammer to remove the snap ring.
< CAUTION >
• There are two E-rings attached, so remove them one by
one. Screwdriver
• Do not reuse the E-rings.
• Do not damage the planet carrier shaft.

Screwdriver

Planet Carrier Shaft

E Ring E007065E

EZ9085E

-104-
 (2) Remove the clutch from the planet carrier shaft.

Clutch

Planet Carrier Shaft

EZ9086E

<Disassembly Procedure>
1 Push in. 2 Rotate to release the lock. 3 Remove the clutch.
Planet Carrier Shaft Clutch
Rotate

Pinion Side
E011784E

(3) Remove the bearing and washer from the planet car-
rier shaft. Internal Gear
< CAUTION >
• Do not reuse the cantilever type planetary carrier shaft.

Washer

E007114E

-105-
 (4) Remove the wave washer and internal gear from the
shock absorber bearing. Shock Absorber Wave Washer
Bearing

Internal Gear E007115E

b. Center Impeller Type PS Starter

(1) Remove the clutch & bearing and the drive lever
from the drive housing. Drive Lever

Drive Housing

Clutch & Bearing

E000847E

(2) Place the pipe (ϕ12) over the clutch shaft, and push down the stop collar (towards the lower side).

Pipe
Clutch

Stop Collar

E000848E

Press

Clutch Shaft
Snap Ring
Pipe Stop Collar

E000849E

-106-
 (3) Using snap ring pliers, remove the snap ring.
(4) Remove the stop collar and clutch.
Snap Ring

Clutch

E000850E

(5) Using snap ring pliers, remove the snap ring.

< CAUTION >
• Do not reuse the snap ring.

Snap Ring

E000851E

(6) Remove the shock absorber bearing, wave washer

and washer from the planet carrier shaft.
Internal Gear

Planet
Carrier Shaft

Wave Washer

Shock Absorber Bearing E007102E

-107-
10-3. INSPECTION
< CAUTION >
• The standard values and replacement standards differ according to the starter, so refer to the individual test standards.

A. Armature Inspection
a. Layer Test
(1) Using a growler tester, inspect the armature coil for
a layer short.
Thickness Gauge
The iron does not
Standard Armature
vibrate!

< CAUTION >

• Remove particles such as carbon grains from around the Growler Tester
commutator before inspection.

EC2049E

b. Insulation Test
(1) Using a 500V megger tester, inspect the insulation
between the commutator and armature core. Armature Core

Commutator
Standard Value 0.2MΩ or more.

c. Commutator Step Inspection

M

E009045E

(1) Using a dial gauge, measure the height of the posi-

tion shown in the diagram. In addition, visually check Dial Gauge
the commutator surface for roughness. If the surface
is rough, correct with sandpaper (no. 300).

Standard Value 3.1mm

Replacement Standard 3.8mm or more.
Armature

Block EC2051E

-108-
B. Brush Inspection
a. Using vernier calipers, measure the length in the center of
the brush. Brush

Standard Value 9.0mm

Replacement Standard 6.0mm or less.

< CAUTION >

• Be careful not to get oil on the brush.

Brush Holder

EC2057E

b. Brush Holder Inspection

(1) Using a 500V megger tester, inspect insulation be-
tween the positive (+) and negative (-) side brush - Side
holders.

Standard Value 0.1MΩ or more.

< CAUTION >

• Be careful not to get oil on the brush.
M

+ Side

E005592E

c. Brush Assy Removal

(1) Remove the 3 screws with a screwdriver.

Screws

EZ9074E

-109-
 (2) Remove the brush assy from the end frame.
< CAUTION > Brush Assy
• Do not disassemble the brush assy.

EZ9075E

C. Clutch Inspection
a. For a clockwise rotating clutch, check the pinion gear locks when it is rotated counterclockwise, and that it turns smoothly
when rotated clockwise. (Opposite for a counterclockwise rotating clutch.)
< CAUTION >
• Also check there is no pinion gear wear, damage, resistance or rust, and that the gear rotates smoothly.

<Cantilever Type PS Starter>

(Counterclockwise Rotating Type)
Clutch

Free

Shaft
Lock
E005593E

<Center Impeller Type PS Starter>

(Clockwise Rotating Type)
Clutch
Lock

Free
Pinion Gear E000853E

-110-
D. Magnetic Switch Inspection
a. Return Spring Inspection
(1) Check that the plunger quickly returns to its original
position when it is pushed down and released. Plunger
< CAUTION >
• Do not drop the plunger or return spring.

EC2065E

b. Continuity Inspection
(1) Check continuity between terminal 50 and terminal
C.
Multimeter
< CAUTION >
• When measuring continuity, make sure the tester probe
contacts terminal C. (The bolt and terminal may move up
and down, so do not let the tester probe contact the bolt.)
Terminal
C
Standard Value 1Ω or less.

Terminal 50
Bolt
E014195E

Make contact here.

Terminal

E011787E

(2) Check continuity between terminal 50 and the mag-

netic switch body. Multimeter

Standard Value 2Ω or less.

Terminal 50

Magnetic
Switch
Body
E014196E

-111-
E. Front Bearing Inspection
a. Front Bearing Inspection Procedures
(1) Visually inspect the front bearing to make sure there
is no damage or rust.
Drive Housing
(2) Check the front bearing in the drive housing rotates
smoothly when the planet carrier shaft is inserted in
the front bearing and rotated.
Planet Carrier
< CAUTION > Shaft
• If there is an abnormality in the front bearing, refer to the
service methods below.

Type Service Method

Cantilever Type PS Replace the drive hous-
Starter ing assy.
E007067E
Center Impeller Type PS Replace the front
Starter bearing.

b. Front Bearing Replacement Procedures (Center Impeller Type PS Starter )

(1) Apply a ϕ13mm cylindrical rod to the front bearing,
and then remove the front bearing with the rack Rack Press
press.
Cylindrical Rod
( 13mm)
Drive
Housing

E007068E

-112-
 (2) Set a new front bearing in the drive housing.
(3) As shown in the photograph, apply a 2.0mm thick
plate to the drive housing, and press fit the front
bearing with the rack press. 2.0mm
< CAUTION > Thick Plate
Front
Always perform work with a 2.0mm thick plate applied to the Bearing
drive housing.

Rack Press

2.0mm Thick Plate

2.0mm
E007069E

Drive Housing
Front Bearing

E007066E

< NOTE >

• For example, the thrust race used in the compressor
thrust bearing can be used because it has a thickness of
2.0mm. Thrust Race

DENSO Part Number 047046-0140

E007070E

(4) Measure the protrusion of the front bearing from the

drive housing with vernier calipers, and check it is
within the standard dimension. Front Bearing

Vernier
2.0 +0.4
0 mm Calipers

Drive Housing

E007072E

E007071

-113-
F. Shock Absorber Bearing Clearance Inspection
a. Measure the outer diameter of the planet carrier shaft.

Standard Value 18mm

EC2068

b. Measure the inner diameter of the shock absorber bear-

ing, and deduct the measured outer diameter of the planet
carrier shaft to calculate the clearance.

Standard Value 0.03 - 0.061mm

Replacement Standard 0.10mm or more.

c. If the limit is exceeded, replace the oilless bearing or the

planet carrier shaft.

EC2069

d. Oilless Bearing Replacement Procedures

(1) Place a ϕ20mm cylindrical rod on the bearing as
shown in the photograph on the right, and remove
the bearing with a rack press.
< CAUTION >
• Do not reuse the bearing.

Shock Absorber
Bearing
EZ9089E

(2) Place the bearing case on a level base, and set a

new bearing in it.
(3) Place a ϕ20mm cylindrical rod on the bearing as
shown in the photograph on the right, and assemble
the bearing with a rack press.
< CAUTION >
Press fit until the bearing contacts the base.

-114-
G. End Frame Rear Bearing Inspection
a. Inspect the end frame rear bearing. Only replace the rear
bearing if it is damaged, locked or rusted.
Bearing

End Frame
E000476E

b. Rear Bearing Replacement Procedures

(1) Place a ϕ16mm cylindrical rod on the bearing as
shown in the photograph on the right, and remove
Rack Press
the bearing with a rack press.
< CAUTION >
• Do not reuse the bearing.

Cylindrical
Rod

EZ9076E

(2) Set a new bearing in the end frame.

(3) Place a ϕ20mm cylindrical rod on the bearing as
shown in the photograph on the right, and assemble
the bearing with a rack press.
< CAUTION >
• Use a flat base.
• Press fit the bearing by pressing on the bearing outer rim.
• Press fit the bearing until it contacts the bottom.

Pipe Base
Push the
outer ring. EC1823E

Bearing Press fit until it

contacts the
bottom.
Base

EC1824E

-115-
H. Use a flat base.
a. Secure the drive housing flange in the vise, and assemble
the shock absorber bearing so that the marks are aligned Shock Absorber
Bearing Vise
with the drive housing as shown in the diagram.
< CAUTION >
• Do not tighten the vise excessively when securing the
starter housing. Tightening is sufficient if the housing
does not move.
Protrusions

Drive Housing E000855E

b. Assemble the STT as shown in the diagram.

< CAUTION >
• Align the STT protrusions with the depression in the STT
shock absorber bearing, and set the STT.
Shock Absorber
Bearing
STT (DENSO Part Number) 95028-10170 Drive Housing

E000856E

c. As shown in the diagram, apply torque with the torque

wrench via the STT, and read the sliding torque value Push By Hand
Torque Wrench
when rotation starts. STT

Sliding 38.2•Nm (34.3 - 42.1N•m)

Torque
390kgf•cm (350 - 430kgf•cm)
Standards

Replacement
25N•m (260kgf•cm) or less.
Standard
Drive Housing
E000857E
< CAUTION >
• If the value is outside the replacement standard, replace
the entire shock absorber bearing.
• Never disassemble or clean the shock absorber. Do not reuse if cleaned or disassembled.
• Press down (with your hands) on the wrench so the STT does not separate from the starter housing.

I. Planet Bushing Clearance Inspection

a. Calculate the clearance from diameter "b" of the planet pin
on the planet carrier shaft, and inner diameter "a" of the
Planetary Gear
planet bushing. Planet Carrier Shaft

Standard Value 0.035 - 0.065mm

Replacement Standard 0.10mm or more. Planet
Bushing
b. If the limit is exceeded, replace the planetary gear or the b
planet carrier shaft. a

Planet Pin
EC2080E

-116-
10-4. ASSEMBLY
A. Clutch & Bearing Assembly
a. Assemble the internal gear and wave washer to the shock
absorber bearing.
Shock Absorber Wave Washer
< CAUTION > Bearing
• Assemble the internal gear in alignment with the shock
absorber bearing tab.

Internal Gear E007115E

b. Apply HL50 grease to the spline sections of the shaft ((1)

- (4)). Washer Planet Carrier
Shaft
c. Apply HL50 grease to both sides of the washer, and as-
semble it to the planet carrier shaft. (Washer thickness:
1.5mm.)

EZ9093E

d. Assemble the bearing to the planet carrier shaft.

e. Apply HL50 grease to both sides of the washer, and as- Internal Gear
semble it to the planet carrier shaft. (Washer thickness:
0.4mm.)

Washer

E007114E

-117-
f. Apply HL50 grease to the entire circumference of the
clutch stop ring. Stop Ring

EZ9095E

g. Clutch Assembly (Cantilever Type PS Starter)

(1) Assemble the clutch to the planet carrier shaft.

Clutch

Planet Carrier Shaft

EZ9086E

< CAUTION >

• After assembly, pull the clutch to check it locks in the position shown in the photograph below. If the clutch is easily re-
moved from the planet carrier shaft, reassemble it according to the <Assembly Procedure> in the diagram below.

<Assembly Procedure>
1 2 3
Clutch
Planet Carrier Shaft
Rotate

Push In Pull Back

EZ9098E

-118-
 (2) Set a new E-ring as shown in the diagram below, and
holding it in the pliers, gradually apply force in the po-
sitions indicated by the arrows to assemble it to the
planet carrier shaft. Pliers

< CAUTION >

• Check the E-ring is fully inserted in the groove. E-Ring
• Assemble the E-rings one at a time.
• Place a cloth between the pliers and the planet carrier
shaft to prevent damage to the shaft.
Cloth
E-Ring

EZ9099E
Planet Carrier
Shaft

Cloth

EZ9100E

h. Clutch Assembly (Center Impeller Type PS Starter)

(1) Using snap ring pliers, assemble the snap ring.

Snap Ring

E000851E

(2) Assemble the clutch, and then assemble the stop

collar. Stop Collar

E000854E

-119-
 (3) Assemble the snap ring.
< CAUTION > Planet Carrier Shaft
• Always use a new snap ring.
(a) Insert into stop collar.
(4) Place the stop collar on the snap ring.
Stop Collar

(b) Insert into snap ring.

Snap Ring
Place the stop collar on
(c) the snap ring.
E000858E

B. Oil Seal, Pinion, Clutch & Bearing, and Drive Lever Assembly
a. Apply HL50 grease to the drive lever sliding pin (1) and the
arm ends (2).

EC1815

b. Apply HL50 grease to the exterior of the clutch & bearing

tube (3). (Cantilever type PS starter only.)

* The photograph shows a

cantilever type PS starter. E007073E

c. Apply HL50 grease to the interior of the drive housing oil

seal (4). (Cantilever type PS starter only.) Oil Seal

* The photograph shows a

cantilever type PS starter. E000880E

-120-
d. Assemble the clutch & bearing and the drive lever to the
drive housing. Clutch &
Bearing
< CAUTION >
• When assembling the drive lever arm, insert it into the
clutch & bearing in the position shown by the arrow in the
photograph. Drive
Lever

Drive Housing

EC1818E

• Align the clutch & bearing protrusions with the drive hous-
ing as shown in the photograph.

EC1820

e. Set the spring and pinion gear onto the clutch end. (Can-
tilever type PS starter only.) Pinion Gear

Spring

E000868E

f. Install a new snap ring. (Cantilever type PS starter only.)

Snap Ring
Snap Ring Pliers
Standard Value 14.3mm or less.

< CAUTION >

• Do not open the snap ring more than necessary.
• After assembling the snap ring, check the following di-
mension.

If A > 14.3mm, install another

new snap ring.
Clutch Tip
A
E000863E
EZ9081E

-121-
C. Planetary Gear and Rubber Seal Assembly
a. Install the rubber seal.

E000869

b. Evenly apply HL50 grease to the area around the three

pins (1), and also to the bushing (2).

(2)
(1)

(1)

E000859

c. Assemble the planetary gear to the shift pin.

d. Apply HL50 grease in the center (3) of the planetary gears. (3)

< NOTE >

• Apply until the grease contacts each planetary gear.

e. Apply HL50 grease to the three pin heads (4).

< CAUTION >
• Do not let dirt adhere to the gears.

(4)

EZ9068E
E009047

-122-
D. Brush Assy Assembly
a. Assemble the brush assy to the end frame.
< CAUTION >
Brush Assy
• Make sure there is no grease or oil on the brush.
• Make sure the rubber seal is sealed against the U groove
of the end frame.

EC1825E
EZ9068E

b. Tighten the three screws with a torque driver to secure the

brush assy.

Tightening 1.48N•m (1.18 - 1.77N•m)

Torque 15kgf•cm (12 - 18kgf•cm)

Screws

EC1826E

E. Armature Assembly
a. Apply HL50 grease to the interior of the end frame bear-
ing. End Frame
b. Insert the armature planet carrier shaft into the end frame
bearing, push the end frame against the armature, and
check the return of each brush. Commutator Face

< CAUTION >

• Make sure there is no grease or oil on the commutator
surface.
• Never subject the armature coil or commutator surface to
impact of any kind.

Armature
EC1827E

-123-
c. Set the space ring to the end of the shaft, and install a new
snap ring with the snap ring pliers. Snap Ring Pliers

Snap Ring

Space Ring

E009046E

< CAUTION >

• After installing the snap ring, check the following dimen-
sion.

Standard Value EZ9072E

5.0mm

If A > 5.0mm, install

A

another new snap ring.

E005595E

F. Armature Plate Assembly

a. Assemble the armature plate to the yoke.
< CAUTION > Armature
• Fit the armature plate rotation stopper to the embossed Plate
part of the yoke interior.
• Be sure to assemble the armature plate in the correct di-
rection.

Embossed Rotation
Area Stopped
EC1832E

EC1831E

G. End Frame & Armature Assembly

a. Place a cloth on a cylindrical pipe, and then place the yoke
on the cloth so the surfaces of the armature plate and pipe
are aligned.

Yoke
Yoke

Armature Plate

Pipe

Cloth
EC1834E
EC1833E

< CAUTION >

• Use a clean cloth.
• Make sure there are no metal particles adhering.

-124-
b. Push the yoke down so that the armature plate does not
move, hold the end frame & armature in both hands, and Lead Wire
Rubber
slowly insert it into the yoke to assemble.

End Frame

Armature

Armature Plate Yoke

Notch

EC1835E

E015188E

< CAUTION >

• Be careful not to jam your fingers.
• Align the yoke notch with the rubber area of the lead wire.
• After assembly, make sure the armature plate is properly aligned.
• Be very careful not to damage the magnet.

H. Yoke Assembly
a. Apply HL50 grease to the end of the yoke (housing side).
(Do not apply to the through-bolts.)
Apply HL50 Grease
Yoke

Through-Bolts
E005594E

b. Assemble the yoke to the drive housing.

< CAUTION > Drive Housing
Protrusion
• Align the protrusion on the yoke exterior with the housing
notch.

Notch

Yoke
EC1837E

-125-
c. Tighten the two through-bolts with a torque wrench.
End Frame
Tightening 6N•m (4.5 - 7.5N•m) End Frame Cover

Torque 61kgf•cm (46 - 76kgf•cm)

d. Install the end frame cover.

Yoke Through-Bolt EZ9071E

I. Magnetic Switch Assy Assembly

a. Apply HL50 grease to the plunger hook and sleeve interi-
or.
b. Assemble the plunger hook to the drive lever. Drive Lever

<Plunger>

Plunger Hook
Grease Coating

EC1839E
E005596E

c. Assemble the spring and magnetic switch.

Plunger Spring Magnetic Switch
<Magnetic Switch>

Apply Grease
(Light Coating)

5mm

E005597E
EZ9070E

-126-
d. Tighten the two bolts with a torque driver.

Tightening 7.5N•m (6 - 9N•m) Bolts

Torque 76.5kgf•cm (61 - 92kgf•cm)

EZ9069E

e. Install the lead wire to terminal C and tighten the nut with
the torque wrench. Magnetic Switch

Tightening 10N•m (8 - 12N•m)

Torque 102kgf•cm (82 - 122kgf•cm)

Terminal C Nut

EZ9068E

-127-
J. Standard Work Procedures (Notes on Disassembly and Assembly Processes)
a. Cantilever Typer

PS Type Starter

(How to Read the Tables) No. (or Part Name) Work Item Test Standard Tools

HL50 Grease Coating

(Magnetic Switch) Tightening 10N·m(8-12N·m)

Terminal C Nut
1 Pulling-In Test Pulls in. Torque 102Kgf·cm(82-122Kgf·cm)
2 Pulling-In Holding Test Holds.
3 Return Test Returns smoothly.
(Clutch)
1 Existence of Sliding Rotates in one direction,
and locks in the other. HL50 Grease Coating

There is no cracking, missing teeth

2 Check wear on teeth tips. or abnormal wear.

Mg/sw Tightening 7.5N·m(6-9N·m)

Installation Bolt Torque 76.5Kgf·cm(61-92Kgf·cm)
Cannot be reused.
HL50 Grease Coating

HL50 Grease Coating

Engine Oil
10W - 30 Lubrication

Cannot be reused. HL50 Grease Coating

HL50 Grease Coating

(Shock Absorber etc.)
1 Bearing Bushing Clearance Check 0.03 - 0.10mm. Micrometer, caliper gauge.
38.2N·m(34.3-42.1N·m) Torque wrench,
2 Sliding Torque Check for the Shock Absorber
390Kgf·cm(350-430Kgf·cm) special STT.

Front Bearing During rotation. No damage or locking.

Oil Seal Coat with HL50 grease.
6N·m(4.5-7.5N·m)
Through-Bolt Tightening Torque
Cannot be reused. 61Kgf·cm(46-76Kgf·cm)
Rear Bearing During rotation. No damage or locking.
Snap Ring Check dimensions after installation. 14.3mm or less.
(Brush Holder)
Cannot be reused.
1 Insulation Test 10M or more. 500V megger.
2 Lead Wire Check No open circuits.
3 Spring Check No rusting. Snap Ring
4 Brush Dimension Check Protruding length: 6.0mm. Vernier calipers. Check dimensions after installation.
5.0mm or less.
HL50 Grease Coating HL50 Grease Coating
1.48N·m(1.18-1.77N·m)
End Frame Cover Screw Tightening Torque
15Kgf·cm(12-18Kgf·cm)
(Armature)
1 Insulation Test 10M or more. 500V megger.
2 Coil Layer Test No iron vibration. Growler tester.
3 Commutator Step 3.8mm. Dial gauge.
4 Commutator Roughness Repair Visually. No. 300 sandpaper.
Yoke Ferrite Check No cracking, damage, or adherence of foreign material.
* Grease Application Method
Wipe off the adhering grease and apply new grease.
E011785E

-128-
b. Center Impeller Type

PS Type Starter

(How to Read the Tables) No. (or Part Name) Work Item Test Standard Tools

HL50 Grease Coating

(Magnetic Switch)
1 Pulling-In Test Pulls in. Tightening 10N·m(8-12N·m)
Terminal C Nut
Torque 102Kgf·cm(82-122Kgf·cm)
2 Pulling-In Holding Test Holds.
3 Return Test Returns smoothly.
(Clutch) Coat with HL50 grease.
1 Existence of Rotates in one direction,
Sliding and locks in the other.
2 Check wear There is no cracking, missing
on teeth tips. teeth or abnormal wear.

Mg/sw Tightening 7.5N·m(6-9N·m)

Installation Bolt Torque 76.5Kgf·cm(61-92Kgf·cm)

HL50 Grease Coating

Cannot be reused.
HL50 Grease Coating

Engine Oil
Cannot be reused. 10W - 30 Lubrication

HL50 Grease Coating

(Shock Absorber etc.)

1 Bearing Bushing Clearance Check 0.03 - 0.10mm. Micrometer, caliper gauge.
38.2N·m(34.3-42.1N·m) Torque wrench,
2 Sliding Torque Check for the Shock Absorber
390Kgf·cm(350-430Kgf·cm) special STT.

6N·m(4.5-7.5N·m)
Through-Bolt Tightening Torque
61Kgf·cm(46-76Kgf·cm)

Rear Bearing During rotation. No damage or locking.

Front Bearing During rotation. No damage or locking.

(Brush Holder)
1 Insulation Test 10M or more. 500V megger. Cannot be reused.
2 Lead Wire Check No open circuits.
3 Spring Check No rusting.
Snap Ring
4 Brush Dimension Check Protruding length: 6.0mm. Vernier calipers.
Check dimensions after installation.
5.0mm or less.
HL50 Grease Coating
HL50 Grease Coating

1.48N·m(1.18-1.77N·m)
End Frame Cover Screw Tightening Torque
15Kgf·cm(12-18Kgf·cm)
(Armature)
1 Insulation Test 10M or more. 500V megger.
2 Coil Layer Test No iron vibration. Growler tester.
3 Commutator Step 3.8mm. Dial gauge.
4 Commutator Roughness Repair Visually. No. 300 sandpaper.

Yoke Ferrite Check No cracking, damage, or adherence of foreign material.

* Grease Application Method
Wipe off the adhering grease and apply new grease.
E011786E

-129-
10-5. Magnetic Switch Operation Inspection
< CAUTION >
• Perform each test in a short period of time (3 to 5 seconds).

A. Pulling-In Test
a. Remove the nut and disconnect the lead wire from terminal C.
b. With connections as shown in the diagram

Battery Terminal 50 Terminal C

Battery Body and Terminal C

Pinion gear springs out.

Terminal 50
E016874E

B. Holding Test
a. From the pull-in test conditions, check that the pinion gear remains out even after the test wire is disconnected from ter-
minal C.
b. Remove the ground wire, and check that the pinion gear
returns.
Test Wire
Terminal C

Terminal 50
E016875E

C. Return Test
a. With connections as shown in the diagram

Battery Terminal C
Battery Body and Terminal 50

Terminal C
Pinion gear springs out.

If terminal 50 is removed during this state,

the magnetomotive forces of both coils
will balance out.

Terminal 50
The pinion gear will instantly return. E016876E

10-6. PERFORMANCE TEST

For the performance test, refer to section "GA TYPE STARTER (PINION SHIFT TYPE)". (Reference: "PERFORMANCE
TEST", page 34.)

10-7. TROUBLESHOOTING
For troubleshooting, refer to section "GA TYPE STARTER (PINION SHIFT TYPE)". (Reference: "TROUBLESHOOTING", page 38.)

-130-
11. Heavy-Duty Planetary Type (P Type) Starter
11-1. CONSTRUCTION AND OPERATION
• Basic construction is the same as for the P type starter. As demonstrated by the yoke diameter, the entire size of this
starter is larger, enabling higher output (5.0kW, 8.0kW). The main differences are as follows.

Shunt Coil Terminal

Magnetic Switch
Drive Lever Terminal M
Rear End Frame
Clutch
Terminal
Front Bearing C Brush
Drive Housing
Rear Bearing

Center Housing Armature

Planet Carrier Shaft Ground (G)
Planetary Gear Yoke E010432E

A. Relationship Between Pinion Engagement and the Main Contact

• In a small starter, if the pinion gear teeth collide with the ring gear teeth, the magnetic switch will compress the drive
spring to close the main contact even if the teeth do not engage.
• However in heavy-duty starters there is no drive spring, so the main contact closes only when the pinion gear and ring
gear engage properly. Heavy-duty starters produce a large amount of torque, so this prevents any damage to the teeth
which would result if the main contact closed while the pinion gear was not properly engaged.
B. Adoption of a Shunt Field Coil
• The shunt field coil is wound as shown in the diagram.
• The shunt field coil is wound so that it increases armature Starter Relay
30
torque when the pinion gear collides with the ring gear, in 50
S
order to facilitate smooth engagement.
• The coil is also used for electric brake operation. Key Switch 50
P.C H.C
M

C
Battery
Sn
Magnetic Switch
Series Winding
Shunt Coil

Motor
G
<Starter Wiring Diagram> E010433E

C. Starter Relay
Because the magnetic switch is larger than that in the small starter, current flowing to the starter switch is also greater.
Therefore, a starter relay is used to protect the starter switch.

-131-
12 Heavy-Duty Planetary Type (P Type) Starter Repairs

12-1. INTRODUCTION
A. Cautions for Work
a. Work Environment
(1) Clear and clean the work stand before beginning work.
(2) Do not perform work in humid, dirty or dusty places.
b. Cautions for Disassembly and Reassembly
(1) Regularly tidy the work area to prevent loss of parts.
(2) Do not secure high-precision parts tightly in a vise, or hit them with a hammer.
(3) When installing bolts and nuts, use a torque wrench and torque driver to tighten them to the torque values shown in
the test standards table.

B. List of Preparatory Items

< CAUTION >
• Refer to the "Pinion Shift Type (GA Type) Starter Repair Preparatory Items List" on page 14 for information on STT and
tools not listed below.

-132-
12-2. DISASSEMBLY

Housing Cover
O-Ring

Drive Housing

Clutch

Magnetic Switch
Stop Collar

Planetary Gear
Armature

Armature Plate

Seal

Internal Gear
End Frame

Brush Holder

Lever Pin

Center Housing

Brush

O-Ring

Yoke

E010437E

-133-
A. Magnetic Switch Removal
a. Remove the terminal cover fixing screw.
< CAUTION >
• Not necessary if there is no terminal cover. Screw

E010438E

b. Remove the shunt coil terminal plug, and then remove the
shunt coil terminal fixing nut.

Nut

E010439E

c. Remove the terminal C fixing nut.

Nut

E010440E

d. Remove the two magnetic switch fixing bolts.

Bolts

E010441E

-134-
e. Remove the magnetic switch.

Magnetic Switch

E010442E

B. End Frame Removal

a. Remove the end frame fixing nuts (one large, one small).
Nuts

E010443E

b. Remove the two through-bolts, and then remove the end

frame. Through-Bolts
< CAUTION >
• Do not reuse O-rings.

O-rings E010444E

-135-
C. Brush Holder Removal
a. Remove the thrust washer.

Thrust Washer

E010445E

b. Remove the four brush lead fixing screws.

Brush Lead
Fixing Screw

E010446E

c. Lift up the brush holder until the brush can be removed.

Brush Holder

Brush Lead Fixing Plate

Shunt Plate
E010447E

d. Pinch open the brush spring with long nose pliers to push
the brush slightly to the outside. (Four positions.)
Brush

Brush Spring
E010448E

-136-
e. Remove the brush holder.

Brush Holder

E010449E

D. Yoke Removal
a. Lift up the yoke and remove.

Yoke

E010450E

b. Remove the O-rings on both sides of the yoke.

< CAUTION >
• Do not reuse O-rings.

O-Ring E010451E

-137-
E. Armature and Armature Plate Removal
a. Lift up the armature and remove from the housing.

Armature

Housing

E010452E

b. Remove the ball from the armature

Armature

Ball

E010453E

c. Remove the armature plate and seal.

Armature
Plate

Seal

Housing

E010454E

F. Planetary Gear Removal

a. Remove the three planetary gears.

Planetary Gear

E010455E

-138-
b. Remove the internal gear.

Internal Gear
E010456E

c. Remove the thrust washer.

Thrust Washer
E010457E

G. Drive Housing Removal

a. Mark the assembly position of the drive and center hous-
ing.
< NOTE >
• The center housing has a number of assembly holes, so Marking
the position must be marked to prevent incorrect reas-
sembly.

E010458E

b. Remove the six drive housing fixing bolts with a hexagonal

wrench.

Drive Housing

Bolt
Bolt E010567E

-139-
c. Remove the drive housing.

Drive Housing E010568E

H. Clutch Removal
a. Place the pipe over the clutch shaft, and push down the
stop collar (towards the lower side).

Stop Collar

Pipe

E010569E

b. Use snap ring pliers to remove the snap ring.

Snap Ring

Stop Collar

E010570E

c. Remove the stop collar.

Stop Collar

E010571E

-140-
d. Remove the snap ring with the snap ring pliers.
Snap Ring

E010572E

e. Remove the washer.

Washer

E010573E

f. Push the lever pin with a screwdriver.

Lever Pin

E010574E

g. Remove the lever pin.

< CAUTION >
• Do not reuse the O-rings installed on the lever pin. Lever Pin

O-Ring

E010575E

-141-
h. Remove the clutch and the lever.
Clutch

Lever

E010576E

I. Planet Carrier Shaft Removal

a. Remove the planet carrier shaft from the center housing.

Planet Carrier Shaft

Center Housing E010577E

b. Remove the thrust washer

Thrust Washer

E010578E

-142-
12-3. INSPECTION
A. Armature Inspection
a. Coil Layer Short Inspection
(1) While contacting a piece of iron to the core in paral-
lel, use a growler tester to inspect the armature coil
for a layer short.
Iron
The thickness gauge does not attract
Standard
or does not vibrate.

E010579E

b. Coil Insulation Inspection

(1) Using a 500V megger tester, measure resistance be-
tween the commutator and the armature core.

Standard Value 0.2MΩ or more.

Megger Tester
E010580E

c. Commutator Run-Out Inspection

(1) Support the armature with the two V blocks, and use
a dial gauge to measure the run-out.

Standard Value 0.02mm or less.

Replacement Standard 0.4mm

Level
Block

E010582E

-143-
d. Commutator Outer Diameter Inspection
(1) Using vernier calipers, measure the outer diameter
of the commutator.

Standard Value 44mm

Replacement Standard 43mm

EP2822

e. Commutator Undercut Depth

(1) Install a needle probe on the dial gauge and mea-
sure the step between the segment and the undercut
section.

Standard Value 0.5 - 0.8mm Undercut Depth

Replacement Standard 0.2mm

E010583E

-144-
B. Front Bearing Inspection
a. Front Bearing Inspection Procedures
(1) Visually inspect the front bearing to make sure there
is no damage or rust.
Drive Housing
(2) Check the front bearing rotates smoothly when the Shaft
planet carrier shaft is inserted in the front bearing
and rotated. Replace the front bearing if there is an
abnormality.

Front Bearing
E010584E

b. Replacement Procedure
(1) Place a cylindrical rod on the front bearing, and re-
move the front bearing with a rack press.
Rack Press

Cylindrical Rod

Drive
Housing

E010585E

(2) Press fit the front bearing with a rack press until they
are level with each other.
Rack Press

Drive
Housing

E010586E

-145-
C. Rear Bearing Inspection
a. Inspection
(1) Check there is no abnormal noise or resistance
when the rear bearing is rotated. Replace if there is
an abnormality. Rear Bearing

E010587E

b. Replacement
(1) Using a bearing puller, remove the rear bearing.

Bearing Puller

E010588E

(2) Using a bench press, install a new rear bearing.

Rack Press

Pipe

Armature

E010589E
Gear

-146-
D. Yoke Inspection
a. Field/Shunt Coil Continuity Inspection
(1) Check there is continuity between the field coil termi-
nal and terminal C.

Standard 1Ω or less.

(2) Measure the resistance between the shunt terminal Terminal C

and the shunt plate. Shunt Terminal

(3) Shunt Coil Resistance

P5.0 0.1 - 0.4Ω

Shunt Plate
P8.0 0.5 - 0.8Ω

E010590E

b. Field Coil Replacement Procedures

(1) Using an impact screwdriver, remove the screw.
< CAUTION >
• Do not damage the yoke when using the impact screw-
driver.

(2) Remove the pole core and field coil from the yoke.
(3) Replace the pole core and field coil.

Tightening 29.9N•m (25.5 - 34.3N•m) Impact

Screwdriver
Torque 305kgf•cm (260 - 350kgf•cm)

E010592E

-147-
E. Brush and Brush Holder Inspection
a. rush Inspection
(1) Inspect the brush length, and replace it with a new
brush if it exceeds the use limits. Also replace the
brush if there is significant damage on the contact
area with the commutator.

Standard Value 26mm

Replacement Standard 17mm

b. Brush Spring Inspection

(1) Inspect the brush spring, and replace if it is rusted or
damaged. Brush Length

E010593E

c. Brush Holder Inspection

(1) Using a 500V megger tester, check that there is no
continuity between the brush holder and the plate.

Standard Value 0.1MΩ or more.

E010594

-148-
F. Clutch Inspection
a. Check the pinion gear locks when it is rotated counter
clockwise, and turns smoothly when rotated clockwise.
< CAUTION >
• Also check there is no pinion gear wear, damage, resis-
tance or rust, and that the gear rotates smoothly. Free

Lock E010595E

G. Magnetic Switch Inspection

a. Return Spring Inspection
(1) Check that the plunger quickly returns to its original
position when it is pushed down and released.

E010596

b. Continuity Inspection
(1) Check for continuity between terminal 50 and termi-
nal C. Terminal 50

Standard 1Ω or less.

Terminal C

Multimeter
E010597E

(2) Check for continuity between terminal 50 and termi-

nal Sn. Terminal Sn Terminal 50

Standard 2Ω or less.

Multimeter
E015202E

-149-
H. Clearance Inspection Between the Center Housing and Planet Carrier Shaft
a. Measure the outer diameter (B) of the planet carrier shaft
sliding part.
b. Measure the inner diameter (A) of the brush on the center
housing. Shaft Seal
A B
c. Calculate the clearance from (A) - (B).

Standard Value 0.03 - 0.61mm

Replacement Standard 0.1mm (A - B)

d. If the replacement standard is exceeded, replace the cen- Bushing Outer Diameter of
ter housing or the planet carrier shaft. Replace the center Planet Carrier Shaft
Inner Diameter of
housing if there are any abnormalities such as scratches Center Housing Bushing E010599E

or cracks in the shaft seal.

I. Planet Bushing Clearance Inspection

a. Calculate the clearance from diameter "b" of the planet pin
on the planet carrier shaft, and inner diameter "a" of the
planet bushing. If the replacement standard is exceeded, Planet Carrier Shaft
Planetary Gear
replace the planetary gear or the planet carrier shaft.

Standard Value 0.03mm (example).

Replacement Standard 0.10mm (example). Planet
Bushing
b
a

Planet Pin
E010600E

-150-
12-4. ASSEMBLY
Assembly should be performed in the reverse order to disassembly. Precautions required during assembly are described
in this section.

DENSO No. 50 Grease

10

1
4

DENSO No. 50 Grease

11
7

<Tightening Torque List>

12.5N·m(10.5-14.5N·m) 2.8N·m(2.2-3.4N·m)
1 Magnetic Switch Fixing Bolt 7 Brush Fixing Screw
128kgf·cm(107-148kgf·cm) 29kgf·cm(22-35kgf·cm)
28N·m(26.5-29.4N·m) 3.8N·m(2.9-4.7N·m)
2 Through-Bolt 8 Shunt Terminal Fixing Nut
285kgf·cm(270-300kgf·cm) 39kgf·cm(30-48kgf·cm)
3.9N·m(3.4-4.4N·m) 2.9N·m(0.9-4.9N·m)
3 Ground Terminal Bolt (Small) 9 Terminal M Nuts
40kgf·cm(35-45kgf·cm) 30kgf·cm(10-50kgf·cm)
30.4N·m(27.5-33.5N·m) 1.2N·m(0.5-2.0N·m)
4 Ground Terminal Bolt (Large)
310kgf·cm(280-340kgf·cm) 10 Terminal 50 Nuts 12.5kgf·cm(5-20kgf·cm)
24.5N·m(19.6-29.4N·m) 29.9N·m(25.5-34.3N·m)
5 Terminal C Nuts 11 Pole Core Screw
250kgf·cm(200-300kgf·cm) 305kgf·cm(260-350kgf·cm)
21.5N·m(17.6-25.4N·m)
6 Drive Housing Fixing Bolt
220kgf·cm(180-260kgf·cm)

E010601E

-151-
A. Yoke Assembly Procedures
a. Assemble the yoke and the center housing so that the pro-
truding pin on the yoke is aligned with the groove on the Protruding Pin
center housing. Yoke
Yoke

Groove

Center Housing
E010602E

B. Brush Holder Assembly Procedures

a. Overlay the brush lead fixing plate over the shunt plate and secure with screw.

Brush Holder

Brush Lead Fixing Plate

Shunt Plate
E010447E

Brush Lead
Fixing Screw

E010446E

-152-
C. End Frame Assembly
a. Install the end frame with the O-ring removed.
< CAUTION > End Frame
• If the end frame is installed with the O-ring already in-
stalled, work will be more difficult and the O-ring may get
damaged.

E010603E

b. Install the O-ring.

c. Install the end frame fixing bolts (one large, one small),
and the two through-bolts.

O-Ring

E010604E

-153-
D. Coat the Terminal C Grommet with Silicone Sealant
a. Wipe off any grease adhering to the grommet.
< CAUTION >
• If there is no adhering grease, directly apply the silicone
sealant.

Grommet
Cloth

E010605E

b. Coat the base of the grommet with silicone sealant (Three

Bond 1221C). Turn over the U-shaped grommet flange,
Grommet
and coat the grommet in silicone sealant by moving the
sealant nozzle in the direction of the arrow shown at the
base of the grommet.

E010606E

c. Coat up to the yoke and end frame connection in silicone

sealant (Three Bond 1221C).

Grommet

Yoke
End Frame
E010607E

-154-
d. Coat enough sealant to cover the area shown in the pho-
tograph (while the grommet flange is pulled out).

E010608

e. Lastly, turn over the linear section at the rear end of the
grommet and coat with sealant.

E010609

f. Coat sealant on the boundary between the yoke and end

frame so it connects seamlessly with the sealant in the U
shaped part of the grommet.
g. After coating the sealant, seal the grommet flange against
the yoke and the end frame.

E010610

-155-
12-5. Magnetic Switch Operation Inspection
< CAUTION >
• Perform each test in a short period of time (3 to 5 seconds).

A. Pulling-In Test
a. Remove the nut and disconnect the lead wire from terminal C.
b. With connections as shown in the diagram
Disconnect from Terminal 50
Battery Terminal 50 <Current Flow> terminal C.
Battery Ground Terminal and Terminal C Battery
Terminal C
Terminal 50
Pinion gear springs out.
H.C P.C

Ground
Terminal Terminal C
Ground Terminal
Ground
E010434E

B. Holding Test
a. From the pulling-in test conditions, remove the test wire
from terminal C as shown in the diagram. Check the pinion Terminal 50

gear remains out. <Current Flow>

Remove the ground wire, and verify that the pinion gear Battery Terminal C
returns.
Terminal 50

H.C

Ground
E010435E

C. Return Test
a. With connections as shown in the diagram
Terminal 50
Battery Terminal C <Current Flow> Disconnect
Battery Ground Terminal and Terminal 50 Battery

Terminal C
Terminal C
Pinion gear springs out.

If terminal 50 is removed during this state, P.C

the magnetomotive forces of both coils
will balance out. Terminal 50
H.C Ground Terminal
Ground
The pinion gear will instantly return. E010436E

12-6. PERFORMANCE TEST

For the performance test, refer to section "GA TYPE STARTER (PINION SHIFT TYPE)". (Reference: "PERFORMANCE
TEST", page 34.)

12-7. TROUBLESHOOTING
For troubleshooting, refer to section "GA TYPE STARTER (PINION SHIFT TYPE)". (Reference: "TROUBLESHOOT-
ING", page 38.)

-156-
Published : June, 2004
Second Issue : November, 2004

Edited and published by:

DENSO CORPORATION
Service Department

1-1 Showa-cho, Kariya, Aichi Prefecture, Japan

Printed in Japan 05F050I