Starter Motor: Service and Repair
REPLACEMENT1. REMOVE INTAKE MANIFOLD ASSEMBLY
2. REMOVE WATER BY-PASS PIPE SUB-ASSY
3. REMOVE STARTER ASSY
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter cable.
c. Remove the bolt and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.
4. INSTALL STARTER ASSY
5. INSTALL WATER BY-PASS PIPE SUB-ASSY
6. INSTALL INTAKE MANIFOLD ASSEMBLY
OVERHAUL
1. REMOVE STARTER YOKE ASSY
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
b. Remove the 2 bolts.
c. Remove the 2 bolts and pull out the starter yoke together with the armature from the magnetic switch.
d. Remove the O-ring from the starter yoke.
2. REMOVE MAGNETIC SWITCH ASSEMBLY
a. Remove the 2 screws, and separate the starter switch and starter housing.
b. Then remove the O-ring, starter clutch steel ball, return spring, idler gear and bearing.
3. REMOVE END COVER
a. Remove the 2 screws and end cover.
4. REMOVE STARTER BRUSH HOLDER ASSY
a. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder.
b. Disconnect the brushes, and remove the brush holder.
5. REMOVE STARTER ARMATURE ASSY
6. INSPECT STARTER ARMATURE ASSY
a. If the surface of the commutator is dirty or burned, polish the part with sandpaper (#400) or replace the armature.
b. Check the commutator open circuit.
1. Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segment, replace the armature.
c. Check the commutator ground.
1. Using an ohmmeter, check that there is no continuity between the commutator and armature core.
If there is continuity, replace the armature.
d. Check the commutator circle runout.
1. Place the armature on the V-blocks.
2. Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it with sandpaper (#400) or replace the armature.
e. Using vernier calipers, measure the commutator diameter.
Diameter:
If the diameter is less than the minimum, replace the armature.
f. Measure the undercut depth of commutator.
Depth:
If the undercut depth is less than the minimum, correct it with a hacksaw blade.
g. Inspect the bearings.
1. Check that the bearing rotates smoothly. If necessary, replace them.
h. Replace the front bearing.
1. Using SST, remove the bearing.
2. Using SST and a press, press in a new bearing.
NOTE: Refer to the bearing direction as shown in the illustration.
SST 09820-00030
i. Replace the rear bearing.
1. Using SST, remove the bearing.
SST 09286-46011
2. Using SST and a press, press in a new bearing.
SST 09820-00030
7. INSPECT STARTER YOKE ASSY
a. Inspect the field coil continuity.
1. Using an ohmmeter, check that there is continuity between the lead wire and brush.
If there is no continuity, replace the starter yoke.
b. Inspect the shunt coil continuity.
1. Using an ohmmeter, measure the resistance between the shunt coil terminals.
Standard resistance: 1.5 - 1.9 Ohm at 20 °C (68 °F)
If the resistance is not as specified, replace the starter yoke.
Brush Length:
8. INSPECT BRUSH
a. Using vernier calipers, measure the brush length.
If the length is less than the minimum, replace the brush holder and starter yoke.
9. INSPECT STARTER BRUSH HOLDER ASSY
a. Using an ohmmeter, check that there is no continuity between the positive and negative brush holders.
If there is continuity, replace the brush holder.
Spring Load:
b. Using a pull scale, measure the brush spring load.
If the spring load is less than the minimum, replace the brush springs.
10. INSPECT STARTER CLUTCH SUB-ASSY
a. Check that the starter clutch operates.
If the starter clutch is does not operate, replace it.
11. INSPECT MAGNETIC SWITCH ASSEMBLY
a. Check the pull-in coil continuity.
1. Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, replace the magnetic switch.
b. Check the holding coil continuity.
1. Using an ohmmeter, check that there is continuity between terminals 50 and the switch body.
If there is no continuity, replace the magnetic switch.
c. Replace the magnetic switch terminal kit parts.
1. Remove the 3 nuts, end cover, gasket and plunger.
NOTE: Do not loosen the 3 stud bolts.
2. Using vernier calipers, measure the contact plate wear.
Maximum wear: 0.9 mm (0.035 in.)
If the wear is greater than the maximum, replace the contact plate.
3. Put a wooden block on the contact plate and press it down with a hand press.
Wooden block dimensions:
20 x 33 x 40 mm (0.79 x 1.30 x 1.57 in.)
Pressing force:
980 N (100 kgf, 221 lbf)
NOTE:
- Check the diameter of the hand press ram.
Then calculate the gauge pressure of the press when 980 N (100 kgf, 221 lbf) of force is applied.
Gauge Pressure:
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
4. Using SST, loosen the terminal nuts.
SST 09810-38140
5. Terminal C:
Remove the terminal nut, washer, O-ring, terminal bolt and contact plate.
6. Terminal 30:
Remove the terminal nut, washer, O-ring, terminal bolt and contact plate.
7. Temporarily install these new terminal 30 kit parts:
- Install a new contact plate.
- Install a new terminal bolt.
- Install a new O-ring.
- Install a new washer.
- Install a new terminal nut.
8. Temporarily install these new terminal C kit parts:
- Install a new contact plate.
- Install a new terminal bolt.
- Install a new O-ring.
- Install a new washer.
- Install a new terminal nut.
9. Temporarily tighten the terminal nuts.
10. Tighten the terminal nuts.
- Put a wooden block on the contact plate and press it down with a hand press.
- Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the plastic frame.
11. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
12. Reinstall the plunger, a new gasket and end cover with the 3 nuts.
Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf)
12. INSTALL STARTER ARMATURE ASSY
HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.
a. Apply grease to the armature bearings.
b. Insert the armature into the field frame.
13. INSTALL STARTER BRUSH HOLDER ASSY
a. Place the brush holder on the starter yoke.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.
NOTE: Check that the positive lead wires are not grounded.
c. Install a new O-ring to the groove of the starter yoke.
d. Install the end cover to the starter yoke with the 2 screws.
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
14. INSTALL MAGNET STARTER SWITCH ASSY
a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.
c. Apply grease to the return spring.
d. Insert the return spring into the magnetic switch hole.
e. Place these parts on the starter housing:
1. Place a new O-ring.
2. Place the starter clutch assembly.
3. Place the idler gear.
4. Place the bearing.
f. Install the starter housing to the magnetic switch with the 2 screws.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
15. INSTALL STARTER YOKE ASSY
a. Install a new O-ring to the groove of the starter yoke.
b. Align the protrusion of the starter yoke with the groove of the magnetic switch, and install the starter yoke and armature assembly.
c. Install the starter yoke and armature assembly with the 2 bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
d. Connect the lead wire to terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)