TOYOZU TECHNICAL SCHOOL

FOUNDATION, INC.
ATS NC II TRAINING SESSION
Batch 37
OPENING PRAYER

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concentration so that may we listen, understand, learn
and have peaceful mind and may we always remember
that god is always with us
 Good
Morning!
TTSFI ATS NC II Trainees
 Lesson:
Disassemble and Assemble Starter
Motor Assembly
 ATS NC II Training Session
Objectives:
 Perform disassemble and assemble starter motor

 Apply safety precaution in disassembling and

assembling starter motor
 Lesson:
Disassemble and Assemble Starter
Motor Assembly
Introduction
The common complaints concerning the
starting system generally fall under four categories,
these are: no engine crank, slow engine cranking,
starter motor spins but not turn the engine and
excessive noise.
Introduction
As a knowledgeable car owner or car
technician, it is important to know how to
disassemble and assemble the starter motor so that
any problem with the starter motor can be fixed.
Introduction
Thus, a service manual in this regard will be
useful tool for the task.
 What
is a
service manual?
Service Manual
It is a handbook containing instructions and
specifications for the maintenance and repair of a
certain vehicle. As opposed to workshop manuals
which provide repair and service procedures for
many vehicles including maintenance details of
automotive cars, motorbikes and etc.
Disassemble Starter
Motor
(Direct Drive Type)
1. Disconnect negative terminal cable from battery

CAUTION:
Work must be started after 90 seconds from the
time the ignition switch is turned to the LOCK
position and the negative (-) terminal cable is
disconnected from the battery.
2. Remove starter motor from engine

a. Disconnect the starter connectors

b. Remove the nut and disconnect the starter wire
c. Remove the two bolts that holds the starter
motor.
3. Remove the solenoid switch cable

a. Remove the nut and disconnect the lead wire

from solenoid switch (M) terminal
b. Loosen the two nuts holding the solenoid switch
to the front drive housing.
 3. Remove the magnetic switch cable

c. Lift the solenoid switch up and out to unhook

the plunger from the shift lever.
4. Remove rear end cover of starter motor
a. Remove the two screws and bearing cover
b. Using a feeler gauge, check the armature shaft
thrust clearance between the lock plate and
rear end frame.
4. Remove rear end cover of starter motor
b. Using a feeler gauge, check the armature shaft
thrust clearance between the lock plate and
rear end frame.
4. Remove rear end cover of starter motor

Thrust Clearance:
0.05 – 0.80 mm (0.0020 – 0.0236 in)
4. Remove rear end cover of starter motor
c. Remove the lock plate, spring and rubber.
d. Remove the two through bolts and end cover.
5. Remove carbon brush holder

a. Using a piece of steel wire, hold the spring

back and disconnect the carbon brush from the
carbon brush holder.
b. Disconnect the two carbon brushes and remove
the carbon brush holder.
6. Remove field coil housing from front drive housing

a. Pull apart by hand. If it is hard to pull out, you

may slightly tap it by mallet hammer.
7. Remove armature assembly

a. Remove the shift lever from the starter housing.

b. Pull the armature from the starter housing.
8. Remove starter over-running clutch

a. Using a screwdriver, tap down the stop collar.

b. Using a small screwdriver, pry out the snap
ring.
8. Remove starter over-running clutch

c. Remove the stop collar from the armature shaft.

8. Remove starter over-running clutch

d. If the pinion was difficult to pull out, smooth

the shaft with an oil stone.
8. Remove starter over-running clutch

e. Remove the starter clutch.

9. Check and test the starter motor parts
a. Solenoid switch test
b. Armature assembly test
c. Field coil windings test
d. Over-running clutch check
e. Carbon brush holder check
Assemble Starter
Motor
(Direct Drive Type)
Take Note:

Use high temperature-resistance grease to

lubricate the bearings and sliding parts when
assembling the starter motor.
1. Install starter over-running clutch to armature

a. Place a new stop collar on the armature

shaft.
1. Install starter over-running clutch to armature

b. Tap in the snap ring with a 14 mm socket

wrench then fit it into the shaft groove.
1. Install starter over-running clutch to armature

c. Using a bench vise, compress the snap

ring.
d. Make sure that the snap rings fits
correctly.
1. Install starter over-running clutch to armature

e. Using a screwdriver, tap the pinion to slide

the stop collar on the snap ring.
2. Install shift lever and field coil housing to front
drive housing

a. Apply grease to the shift lever and front

drive housing bushing.
b. Install the shift lever to the front drive
housing.
2. Install shift lever and field coil housing to front
drive housing

c. Install the field coil housing on the front

drive housing and armature assembly.
3. Install carbon brush holder
a. Place the carbon brush holder over the
armature assembly (commutator).
b. Using a piece of steel wire, hold the
carbon brush spring backward direction
and insert the two carbon brush in holder.
4. Install rear end cover
a. Apply grease to the rear end cover
bushing.
b. Install the rear end cover on the armature
shaft.
5. Install field coil housing and armature assembly

a. Align the protrusion of the field frame with

the drive lever.
b. Install the two through bolts
Torque:
7.6 N-m (77 kgf-cm, 67 in-lbf)
6. Install bearing cover

a. Install the rubber, spring and lock plate.

6. Install bearing cover

b. Using a feeler gauge, measure the

armature thrust clearance between the lock
plate and end frame.
Thrust Clearance:
0.05 – 0.60 mm (0.0020 – 0.0236)
6. Install bearing cover

c. Install the bearing cover with the two

screws
7. Install solenoid switch

a. Hook the solenoid switch stud underneath

the drive shift lever spring.
b. Install the two nuts of solenoid switch.
7. Install solenoid switch

c. Connect the lead wire to the M terminal of

solenoid switch with the nut.
Torque:
9.8 N-m (100 kgf-cm, 87 in,- lbf)
Disassemble Starter
Motor
(Reduction Type)
1. Disconnect negative terminal cable from battery

CAUTION:
Work must be started after 90 seconds from the
time the ignition switch is turned to the LOCK
position and the negative (-) terminal cable is
disconnected from the battery.
2. Remove starter motor from engine

a. Disconnect the starter connectors

b. Remove the nut and disconnect the starter wire
c. Remove the two bolts that holds the starter
motor.
3. Remove the field frame housing and armature
a. Remove the nut, and disconnect the lead wire
from the M terminal of solenoid switch.
3. Remove the field frame housing and armature
b. Remove the two through bolts
c. Pull out the field frame housing together with
the armature.
4. Remove starter housing, clutch assembly and gears

a. Remove the two screws

4. Remove starter housing, clutch assembly and gears

b. Removing the following parts from the solenoid

switch:
1. Starter housing
2. Idler hear and bearing
3. Clutch assembly
4. Return spring
5. Remove steel ball
a. Using a magnetic finger, remove the steel ball
from the clutch shaft hole.
6. Remove carbon brushes and brush holder
a. Remove the two screws and rear end cover from
the field frame housing.
6. Remove carbon brushes and brush holder
b. Using a screwdriver, hold the spring back and
disconnect the four carbon brush from the
carbon brush holder.
c. Remove the carbon brush holder.
7. Remove armature from field frame housing.
8. Conduct check and test starter motor
Assemble Starter
Motor
(Gear Reduction Type)
Take Note:

Use high-temperature grease to lubricate

the bearings and gears when assembling
the starter motor.
1. Place the armature into field frame housing.
a. Apply grease to the armature bearings and insert
the armature into the field frame housing.
2. Install carbon brush holder
a. Place the carbon brush holder on the armature’s
commutator.
b. Using a screwdriver, hold the carbon brush
spring back and connect the four carbon brush
into the brush holder.
Take Note:

Check that the positive (+) lead wires are

connected to field coil windings and not
grounded. The negative (-) are connected
to the holder
2. Install carbon brush holder
c. Install the rear end cover to the field frame
housing with the screws

Torque:
1.5 N-m (15 kgf-cm, 13 in-lbf)
3. Insert steel ball into clutch shaft hole
a. Apply grease to the steel ball
b. Insert the steel ball into the clutch shaft hole.
4. Install clutch assembly, gear and starter motor
housing

a. Apply grease to the return spring

b. Insert the return spring into the solenoid switch
hole.
4. Install clutch assembly, gear and starter motor
housing

c. Place the following parts in position on the

starter motor housing:
1. Clutch assembly
2. Idler gear and bearing.
4. Install clutch assembly, gear and starter motor
housing

d. Install the starter motor housing to solenoid

switch with the two screws:
Torque:
9.3 N-m (95 kgf-cm, 82 in-lbf
5. Install field frame housing and armature assembly

a. Align the protrusion of the field frame with

groove or the solar witch.
5. Install field frame housing and armature assembly

b. Install the field frame housing and

armature with the two through bolts
Torque:
9.3 N-m (95 kgf-cm 82 in lbf
5. Install field frame housing and armature assembly or
housing

c. Connect the lead wire of M terminal with a

nut.
Torque:
7.9 N-m (81 kgf-cm, 70 in-lbf)
Done……
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YOU!!!