Starter Repair Procedures

Removal

1. 1
   Disconnect the negative battery cable.
2. 2
   Remove the air duct and air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner")
3. 3
   Disconnect the starter cable (A) from the B terminal of the solenoid, then disconnect the connector from the S (B) terminal.

   

4. 4
   Remove the 2 bolts securing the starter, then remove the starter (A).

   

Installation

1. Install in the reverse order of removal. Starter mounting bolt: 49.0 ~ 64 N·m

Disassembly

1. 1
   Disconnect the M terminal (A) on the magnetic switch unit.

   

2. 2
   Loosen the screws (A), then disconnect the magnetic switch assembly (B).

   

3. 3
   Loosen the through bolts (A).

   

4. 4
   Remove the brush holder assembly (A), armature assembly (B), and yoke assembly (C).

   

5. 5
   Remove the packing plate (A) and the lever stopper (B).

   

6. 6
   Remove the gear reduction assembly (A) and the lever (B).

   

7. 7
   Press the stopper (A) using a socket (B).

   

8. 8
   After removing the snap ring (A) using pliers (B).

   

9. 9
   Remove the stopper (A), overrunning clutch (B), and internal gear (C).

   

   Using a suitable puller (A), push the overrunning clutch stopper (C) onto the snap ring (B).

   

10. 10
    Assembly is the reverse of disassembly.

Installation

1. Assemble in the reverse order of disassembly.

Inspection

Starter Solenoid Inspection

1. 1
   Disconnect the lead wire from the M terminal of the magnetic switch.
2. 2
   Connect the battery as shown in the illustration. If the starter pinion gear moves out, it is in good condition.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

3. 3
   Disconnect the battery from the M terminal. If the pinion gear does not retract, the hold-in coil is operating correctly.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

4. 4
   Also disconnect the battery from the housing. If the pinion gear retracts immediately, it is operating correctly.

   To prevent damage to the starter, do not keep the battery connected for more than 10 seconds.

   

No-Load Test

1. 1
   Place the starter in a vise with soft jaws and connect a fully charged 12-volt battery to the starter as follows.
2. 2
   Connect a test ammeter (150 A scale) and carbon pile rheostat as shown in the illustration.
3. 3
   Connect a voltmeter (15-volt scale) to the starter.

   

4. 4
   Turn the carbon pile to the OFF position.
5. 5
   Connect the battery cable from the negative battery terminal to the starter housing.
6. 6
   Adjust until the battery voltage shown on the voltmeter reads 11 volts.
7. 7
   Make sure the maximum current is within specification and that the starter rotates smoothly and freely.

   Items	Specification
   Current (A)	Max. 70
   Speed (rpm)	Min. 2400

8. 8
   Remove the starter motor.
9. 9
   Disassemble the starter as shown at the beginning of this procedure.
10. 10
    Inspect the armature for wear or damage from contact with the permanent magnet. If wear or damage is found, replace the armature.

    

11. 11
    Inspect the commutator surface (A). If the surface is dirty or burnt, grind it with sandpaper or on a lathe within specification, or polish with #500 or #600 sandpaper (B).

    

12. 12
    Check the commutator diameter. If the diameter is below the limit, replace the armature. Commutator Diameter. Standard (new): 27.0 mm (1.06 in). Service limit: 26.0 mm (1.02 in).

    

13. 13
    Measure the commutator runout (A).

    A.	If the commutator runout is within the limit, check the commutator for carbon dust or brass chips between the segments.

    B.	If the commutator runout exceeds the service limit, replace the armature.

    Commutator Runout. Standard (new): 0.05 mm (0.0019 in). Maximum service limit: 0.08 mm (0.0031 in).

    

14. 14
    Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw to the specified depth. Cut out all mica (C) between the commutator segments. The undercut must not be too shallow, too narrow or V-shaped (D). Commutator Mica Depth. Standard (new): 0.8 mm (0.0314 in). Limit: 0.2 mm (0.0079 in).

    

15. 15
    Check the continuity between the commutator segments. If there is an open circuit between any segments, replace the armature.

    

16. 16
    Using an ohmmeter, check that there is no continuity between the commutator (A) and the armature coil core (B), and between the commutator and the armature shaft (C). If there is continuity, replace the armature.

    

    

    

17. 17
    Slide the overrunning clutch along the shaft. Replace it if it does not slide smoothly.
18. 18
    Rotate the overrunning clutch in both directions. Does it lock in one direction and rotate smoothly in the opposite direction? If it does not lock in either direction, or locks in both directions, replace it.

    

19. 19
    If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly (the pinion gear is not sold separately). Check the condition of the flywheel or drive plate ring gear if the starter pinion teeth are damaged.

Armature Inspection and Test. Inspect the starter brushes. Brushes that are worn or contaminated with oil must be replaced. Starter Brush Holder Test. Make sure there is no continuity between the (+) brush holder (A) and the (-) plate (B). If there is continuity, replace the brush holder assembly. Overrunning Clutch

Cleaning

1. 1
   Do not immerse parts in cleaning solvent. Immersing the yoke and/or armature assembly may damage the insulation. Wipe these parts with a cloth only.
2. 2
   Do not immerse the drive in cleaning solvent. The overrunning clutch is pre-lubricated at the factory, and solvent will wash the lubricant out of the clutch.
3. 3
   The drive may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.