Starter Motor

Specifications

Specification

Components and Component Location

Components

[NOT ISG Type]

Description and Operation

Description

The starting system includes the battery, starter motor, magnetic switch, ignition switch, neutral safety switch (A/T), clutch pedal position switch (M/T), ignition lock switch, connecting wires, and battery cable.

When the ignition key is turned to the START position, current flows and energizes the starter solenoid coil.

The solenoid plunger and shift lever are activated, and the pinion gear engages with the ring gear. The contacts close and the starter cranks the engine.

To prevent damage caused by excessive rotation of the starter armature, the pinion gear overrunning clutch disengages when the engine starts.

In combination with the ISG function, the starter must perform much more work. Therefore, the starter is designed for a significantly higher number of starting cycles. The starter components are adapted to these higher requirements.

1. Solenoid 2. Brush Assembly 3. Armature 4. Overrunning Clutch

Circuit Diagrams

Wiring Diagram

Repair Procedures

Removal

1. 1

   Turn the ignition switch OFF and disconnect the negative (-) battery terminal.

2. 2

   Remove the air cleaner.

   (Refer to Engine Mechanical System – Air Cleaner)

3. 3

   Remove the upper starter mounting bolt (A).

   Starter upper mounting bolt:

   49,0–64 N·m

   

4. 4

   Remove the engine room cover.

   (Refer to Engine Mechanical System - "Engine Room Cover")

5. 5

   Remove the vacuum pump.

   (Refer to Brake System - "Vacuum Pump")

6. 6

   Disconnect the starter cable (A) from the solenoid B terminal, then disconnect the connector (B) from the S terminal.

   Starter solenoid "B" terminal mounting nut:

   9,8–11.8 N·m

   

7. 7

   Remove the lower starter mounting bolt (A).

   Starter lower mounting bolt:

   49,0–64 N·m

   

8. 8

   Remove the starter (A).

   

Installation

1. Install in the reverse order of removal.

Disassembly

[NOT ISG Type]

1. 1

   Disconnect the M terminal (A) on the magnetic switch assembly.

   

2. 2

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

   

3. 3

   Loosen the brush holder mounting screws (A) and the through bolts (B).

   

4. 4

   Remove the rear bracket assembly (A) and the brush holder assembly (B).

   

5. 5

   Remove the fork assembly (A).

   

6. 6

   Remove the seal (A), lever plate (B), lever (C), and armature assembly (D).

   

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 snap ring (B), stopper (A), overrunning clutch (C) and armature (D).

   

   

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 pops out, the starter is operating normally.

   

3. 3

   Disconnect the battery from terminal M.

   If the pinion gear does not retract, the hold-in coil is operating normally.

   

4. 4

   Disconnect the battery from the housing as well. If the pinion gear retracts immediately, the starter is operating normally.

   

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 the carbon pile rheostat as shown. 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 motor housing.

6. 6

   Adjust until the battery voltage shown on the voltmeter reads 11.5 volts.

7. 7

   Make sure the maximum current is within specification and that the starter rotates smoothly and freely.

   Current (Max.)	Speed (Min.)
   60 A	5500 rpm

Armature

1. 1

   Remove the starter motor.

2. 2

   Disassemble the starter as shown at the beginning of this procedure.

3. 3

   Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or damage, replace the armature.

   

4. 4

   Inspect the commutator surface (A). If the surface is dirty or burnt, correct it with a lathe according to the following specifications, or repair it with #500 or #600 sandpaper (B).

   

5. 5

   Measure the commutator diameter. If the diameter is less than the service limit, replace the armature.

   Commutator diameter

   Standard (new): 29.4 mm (1.1575 in)

   Service limit: 28.8 mm (1.1339 in)

   

6. 6

   Measure the commutator runout (A).

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

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

   Commutator runout

   Standard (new): 0.05 mm (0.0020 in) max.

   Service limit: 0.10 mm (0.0039 in) max.

   

7. 7

   Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw to the correct depth. Remove 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): 0.5 mm (0.0197 in)

   Limit: 0.2 mm (0.0079 in)

   

8. 8

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

   

9. 9

   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.

   

Starter Brush

1. Brushes that are worn or contaminated with oil must be replaced.

   Brush length

   Standard: 12.3 mm (0.4843 in)

   Service limit: 5.5 mm (0.2165 in)

   

Starter Brush Holder

1. 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

1. 1

   Slide the overrunning clutch along the shaft.

   Replace it if it does not slide smoothly.

2. 2

   Turn the overrunning clutch in both directions.

   Does it lock in one direction and rotate smoothly in the other? If it does not lock in either direction, or locks in both directions, replace it.

   

3. 3

   If the starter pinion gear is worn or damaged, replace the overrunning clutch assembly. (The gear is not sold separately.)

   Inspect the flywheel ring gear or drive plate if the starter pinion gear teeth are damaged.

Cleaning

1. 1

   Do not immerse parts in cleaning solvent.

   Immersing the yoke assembly and/or armature 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 off the clutch.

3. 3

   The drive may be cleaned with a brush moistened with cleaning solvent, and then wiped dry with a cloth.