11-1

STARTING SYSTEM
Page 0
SST TO BE USED ............................................ 11-2
1
STARTER MOTOR........................................... 11-3
COMPONENTS......................................................... 11-3
2
REMOVAL·INSPECTION·INSTALLATION .............. 11-4 3
DISASSEMBLY·INSPECTION·REASSEMBLY........ 11-5
STARTER MOTOR ASSY UNIT INSPECTION ...... 11-10
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6
7
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11-2

SST TO BE USED
Illustration Part No. Part name

09286-76001-71
Injection pump spline shaft puller
(09286-46011)
 11-3

STARTER MOTOR
COMPONENTS
1904 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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11-4

REMOVAL·INSPECTION·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

Removal·Installation Procedure
The installation procedure is the reverse of the removal procedure.
No. Item Removal Inspection Installation
1 Battery
2 Battery set plate
3 Disconnect the connectors and the terminals.
4 Starter ASSY
 11-5

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

0
2 1
2
5 4 3
4
1
10
11

5
6

12
6
9 7
8
8
7
9
10
Disassembly·Reassembly Procedure 11
The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly 12
1 Lead wire
2
3
Yoke ASSY
End frame
[Point 1] [Point 11]
[Point 10]
13
4
5
Brush
Armature ASSY
[Point 2] [Point 3]
[Point 4]
[Point 9]
14
6 Bearing [Point 5] [Point 8]
7 Housing ASSY [Point 6] 15
8 Clutch ASSY [Point 7]
9
10
Steel ball
Idler gear
16
11
12
Retainer, roller
Return spring
17
Caution:
Apply grease to the steel ball, idler, gear starter clutch and return spring on reassembly.
18
11-6

Point Operations
[Point 1]
Inspection:
Inspect for continuity between the field coil brush and C
terminal.
Standard: Continuity exists.

Inspection:
Inspect the insulation between the field coil brush and the field.
Standard: 0.1 MΩ or more

[Point 2]
Brush holder
Disassembly:
Lift up the brush spring on the plus side with long-nose pliers.
Take care not to damage the brush or the commutator.

Brush Brush
spring

[Point 3]
Inspection:
Inspect the brush.
1. Inspect for roughness of the contact surface and the length of
the brush.
Measure the brush length in the center section (concave part).
Standard: 20.5 mm (0.807 in.)
Limit: 13.0 mm (0.512 in.)
2. When correcting the contact surface and replacing the brush,
wrap sand paper around the commutator to correct the contact
surface.
 11-7

Inspection:
Check that the brush spring movement is smooth, then
measure the applied load of the spring.
Standard: 31.4 to 39.2 N (3.2 to 4.0 kgf) [7.1 to 8.8 lbf]
Limit: 21.6 N (2.2 kgf) [4.9 lbf]

Brush

Brush spring

Inspection:
Inspect the insulation between the brush holder on the plus
side and the brush holder on the minus side.
Standard: 0.1 MΩ or more

[Point 4]
Inspection:
Inspect the insulation between the commutator and the
armature coil.
Standard: 1 MΩ or more

Inspection:
Perform a short circuit test on the armature coil.
1. Remove completely any deposits on the surface of the
armature.
2. Using an armature tester, place an iron piece in parallel
contact to the armature and turn the armature.
Standard: The iron piece should not be attracted or
vibrate.

Inspection:
Inspect for continuity between each segment of the armature
coil.
Standard: There should be continuity between all
segments of the armature.
11-8

Inspection:
Inspect the commutator.

1. Measure the runout of the periphery.

Limit: 0.05 mm (0.0020 in.) or less

2. Measure the outside diameter.

Standard: 30 mm (1.18 in.)
Limit: 29 mm (1.14 in.)

3. Measure the undercut depth between the segments.

Standard: 0.5 to 0.8 mm (0.020 to 0.031 in.)
Limit: 0.2 mm (0.008 in.)

[Point 5]
SST
Disassembly:
Use the SST to remove the bearing.
SST 09286-76001-71
(09286-46011)

[Point 6]
C terminal Inspection:
Inspect the magnetic switch.
1. Inspect for continuity between the 50 terminal and the C
terminal.
Standard: Continuity exists.

50 terminal
 11-9

2. Inspect for continuity between the 50 terminal and the

Magnetic switch body magnetic switch body.
Standard: Continuity exists.

50 terminal

[Point 7]
Free Inspection:
Inspect the clutch and the gear.
1. Inspect for wear and damage to the gear.
Lock
2. Check that the gear locks when rotated in the drive direction
(left) and rotates smoothly when rotated in the opposite
direction (right).

[Point 8]
Reassembly:
Use a press to press fit the bearing.

[Point 9]
Reassembly:
Reassemble the brushes.
1. Lift the brush spring up with a screwdriver etc, and reassemble
the brush holder into the starter yoke.
2. Pull the brush spring up and reassemble the brush into the
brush holder.

[Point 10]
Reassembly:
Align the notch (a) in the end frame and the lead wire grommet
(b).

(a) (b)
11-10

[Point 11]

Notch Reassembly:
Align the notch in the yoke with the protruding section of the
magnetic switch.

STARTER MOTOR ASSY UNIT INSPECTION

Note:
Perform each test for a short time (3 to 5 seconds).
C terminal
1. Pull-in test
Check that the pinion gear pops out when the ASSY is
connected as shown in the illustration.

50 terminal

2. Holding coil holding test

From the pull-in test status, check that the pinion gear remains
popped out even after the C terminal wire is disconnected.

3. Plunger return test

Check that the pinion gear returns from the holding test status
of the holding coil when the terminal is disconnected as shown
in the illustration on the left.

4. No-load test
(1) Secure the starter motor with a vice.
50 terminal (2) During a no-load test, a large current will flow through the
lead wire, so use a thick lead wire.
(3) Read the ammeter once the display has settled.

30 terminal Standard: 90 A or less