1FS RM.

book 1 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-1

STARTING SYSTEM

SST LIST .......................................................................... 8-2

STARTER MOTOR ........................................................ 8-3 0
COMPONENTS ............................................................... 8-3
1
DISASSEMBLY, INSPECTION
AND REASSEMBLY .................................................... 8-4 2
STARTING MOTOR ASSY 3
INDIVIDUAL INSPECTION .......................................... 8-9
4
5
6
7
8
9
10
11
12
13
14
1FS RM.book 2 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-2

SST LIST
Illustration Part No. Part Name

09286-76001-71
Injection pump spline shaft puller
(09286-46011)
1FS RM.book 3 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-3

STARTER MOTOR
COMPONENTS
1904
1FS RM.book 4 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-4

DISASSEMBLY, INSPECTION AND REASSEMBLY

5 4

1
10
11

12

Disassembly and reassembly procedure

The reassembly procedure is the reverse of the disassembly procedure.
No. Item Disassembly Inspection Reassembly
1 Lead wire
2 Yoke ASSY [Point 1] [Point 11]
3 End frame [Point 10]
4 Brush [Point 2] [Point 3] [Point 9]
5 Armature ASSY [Point 4]
6 Bearing [Point 5] [Point 8]
7 Housing ASSY [Point 6]
8 Clutch ASSY [Point 7]
9 Steel ball
10 Idler gear
11 Retainer, roller
12 Return spring

Caution:
Apply grease to the steel ball, idler gear, starter clutch, and return spring in assembling.
1FS RM.book 5 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-5

Point operation
[Point 1]
Inspection:
Check the continuity between the field coil brush and lead wire.
Standard: Continuity exists.

Inspection:
Check the insulation between the field coil brush and field.
Standard: 0.1 MΩ minimum

[Point 2]
Brush holder
Disassembly:
Raise the brush spring at the positive side using a long-nosed plier.
Be careful not to damage the brush or commutator.

Brush
Brush spring

[Point 3]
Inspection:
Inspect the brush.
1. Check for roughness of the contact surface and brush length.
Measure the brush length at the center (concave area).
Standard: 20.5 mm (0.8071 in.)
Limit: 13.0 mm (0.5118 in.)
2. To smooth the contact surface or change the brush, wrap
sandpaper around the commutator and smooth the contact
surface.

Inspection:
Check that the brush spring moves smoothly and then measure the
installation load.
Standard: 31.4 to 39.2 N
Limit: 21.6 N

Brush

Brush spring
1FS RM.book 6 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-6

Inspection:
Check the insulation between the brush holders at positive and
negative sides.
Standard: 0.1 MΩ minimum

[Point 4]
Inspection:
Check the insulation between the commutator and armature coil.
Standard: 0.1 MΩ minimum

Inspection:
Perform short-circuit test on the armature coil.
1. Remove foreign matters thoroughly from the armature surface.
2. Rotate the armature while placing a piece of iron parallel to the
armature using the armature tester.
Standard: No attraction or vibration occurs on a piece of
iron

Inspection:
Check the continuity between segments of the armature coil.
Standard: Continuity exists between all segments.

Inspection:
Inspect the commutator.
1. Measure the ellipticity.
Limit: 0.05 mm (0.0020 in.) or less
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8-7

2. Measure the outside diameter.

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

3. Measure the depth of undercut between segments.

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

[Point 5]
Disassembly:
SST
Remove the bearing using SST.
SST 09286-76001-71
(09286-46011)

[Point 6]
Inspection:
Inspect the magnetic switch.
1. Check the continuity between the ST and C terminals.
Standard: Continuity

Terminal C

Terminal ST

2. Check the continuity between the ST terminal and magnetic

Magnet switch body switch body.
Standard: Continuity

Terminal ST
1FS RM.book 8 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-8

[Point 7]
Inspection:
Free Inspect the clutch and gear.
1. Inspect the gear for wear and damage.
2. Check that the gear is locked by turning it in the drive direction
Lock (left) and rotates smoothly by turning it in the reverse direction
(right).

[Point 8]
Reassembly:
Press the bearing into place using a press machine.

[Point 9]
Reassembly:
Assemble the brush.
1. Raise the brush spring using a screwdriver or the like and
install the brush holder to the starter yoke.
2. Pull the brush spring up and install the brush to the brush
holder.

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

(a) (b)

[Point 11]
Reassembly:
Cutout Align the notch of the yoke with the protrusion of the magnetic
switch.
1FS RM.book 9 ページ ２０１３年９月２７日　金曜日　午後１２時４１分

8-9

STARTER ASSY INDIVIDUAL INSPECTION

Note:
Each test should be performed in a short period
(3 to 5 seconds).
1. Pull-in test
Check that the pinion gear comes out with the connection
shown in the figure.
Terminal ST
Battery
Terminal C

2. Holding coil test

Disconnect the C terminal under the pull-in test condition to
see if the pinion gear remains out.
Disconnect

Battery

3. Pinion gear return test

Check that the pinion gear returns when the terminal is
disconnected as shown in the left figure under the holding coil
test condition.

Disconnect Battery

4. No-load test
(1) Fix the starter securely with a vise or the like.
Terminal ST (2) Use a thick lead wire since large current is passed
through the lead wire for no-load test.
(3) Read the ammeter when the indication becomes stable.
Standard: 90A or less

Battery
Terminal B
Ammeter