Starter¶

Removal of starter¶

1. Disconnect cable from negative terminal of battery.

   Caution

   Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (–) terminal cable is disconnected from the battery.

2. Remove LH engine hood side panel.

3. Remove air cleaner.

   • 3S-GTE (See Cylinder block (3S-GTE) › Removal of engine, step 9)
   • 5S-FE (See Cylinder block (5S-FE) › Removal of engine, step 9)

4. Remove starter.

   1. Remove the terminal cover.
   2. Remove the nut, and disconnect the starter cable.
   3. Remove the nut, and disconnect the starter wire.
   4. Disconnect the starter connector.
   5. Remove the two bolts, wire clamp and starter.

   

Components¶

1.0 kW type

1.4 kW (Conventional) and 1.6 kW types

1.4 kW (Compact) type

Disassembly of starter¶

(See Removal of starter)

1. Remove field frame and armature.

   1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
   2. Remove the two through bolts, and pull out the field frame together with the armature.
   3. (1.4 kW and 1.6 kW Types)
      Remove the O-ring from the field frame.

   

2. Remove starter housing, clutch assembly and gear(s).

   1. Remove the two screws.

      

   2. Remove the following parts from the magnetic switch:

      (1.0 kW and 1.4 kW (Compact) Types)

      • Starter housing and clutch assembly
      • Return spring
      • Bearing
      • Idler gear

      

      (1.4 kW (Conventional) and 1.6 kW Types)

      • Starter housing and clutch assembly
      • Return spring
      • Pinion gear
      • Bearing
      • Idler gear

      

3. Remove steel ball.

   Using a magnetic finger, remove the steel ball from the clutch shaft hole.

   

4. Remove brush holder.

   1. Remove the two screws, two O-rings (1.4 kW and 1.6 kW types) and end cover from the field frame.
   2. (1.4 kW and 1.6 kW Types)
      Remove the O-ring from the field frame.
   3. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the four brushes, and remove the brush holder.

   

   

5. Remove armature from field frame.

Inspection and repair of starter¶

Armature coil¶

1. Inspect commutator for open circuit.

   Using an ohmmeter, check that there is continuity between the segments of the commutator.

   If there is no continuity, replace the armature.

   

2. Inspect commutator for ground.

   Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.

   If there is continuity, replace the armature.

   

Commutator¶

1. Inspect commutator for dirty and burnt surface.

   If the surface is dirty or burnt, correct with sandpaper (No.400) or on a lathe.

2. Inspect commutator for runout.

   1. Place the commutator on V-blocks.
   2. Using a dial indicator, measure the circle runout.

   Maximum circle runout: 0.05 mm (0.0020 in.)

   If the circle runout is greater than maximum, correct it on a lathe.

   

3. Inspect commutator diameter.

   Using vernier calipers, measure the diameter.

   • Standard diameter: 30.0 mm (1.181 in.)
   • Minimum diameter: 29.0 mm (1.142 in.)

   If the diameter is less than minimum, replace the armature.

   

4. Inspect undercut depth.

   Check that the undercut depth is clean and free of foreign material. Smooth out the edge.

   • Standard undercut depth: 0.6 mm (0.024 in.)
   • Minimum undercut depth: 0.2 mm (0.008 in.)

   If the undercut depth is less than minimum, correct it with a hacksaw blade.

   

Field coil (field frame)¶

1. Inspect field coil for open circuit.

   Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.

   If there is no continuity, replace the field frame.

   

2. Inspect field coil for ground.

   Using an ohmmeter, check that there is no continuity between the field coil end and field frame.

   If there is continuity, replace the field frame.

   

Brushes¶

1. Inspect brush length.

   Using vernier calipers, measure the brush length.

   Standard length:

   • 1.0 kW type – 13.5 mm (0.531 in.)
   • 1.4 kW and 1.6 kW types – 15.5 mm (0.610 in.)

   Minimum length:

   • 1.0 kW type – 8.5 mm (0.335 in.)
   • 1.4 kW and 1.6 kW types – 10.0 mm (0.394 in.)

   If the length is less than minimum, replace the brush holder and field frame.

   

Brush springs¶

1. Inspect brush spring load.

   Take the pull scale reading the instant the brush spring separates from the brush.

   Standard installed load: 1.79 – 2.41 kg (3.9 – 5.3 lb, 18 – 24 N)

   If the installed load is not as specified, replace the brush springs.

   

Brush holder¶

1. Inspect brush holder insulation.

   Using an ohmmeter, check that there is no continuity between the positive (+) and negative (–) brush holders.

   If there is continuity, repair or replace the brush holder.

   

Clutch and gears¶

1. Inspect gear teeth.

   Check the gear teeth on the pinion gear, idler gear and the clutch assembly for wear or damage.

   If damaged, replace the gear or clutch assembly.

   If damaged, also check the flywheel ring gear for wear or damage.

2. Inspect clutch pinion gear.

   Rotate the pinion gear counterclockwise and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.

   If necessary, replace the clutch assembly.

   

3. If necessary, replace clutch assembly.

   A. Disassemble starter housing and clutch assembly

   1. Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar.

      

   2. Push down the pinion gear.

   3. Using a plastic-faced hammer, tap down the stop collar.

      

   4. Using a screwdriver, pry out the snap ring.

      

   5. Disassemble the following parts:

      • Stop collar
      • Pinion gear
      • Compression spring
      • Starter housing
      • Spring retainer
      • Bearing retainer (Ex. 1.4 kW (Compact) Type)
      • Starter clutch
      • Compression spring
      • Clutch shaft

      

   B. Assemble starter housing and clutch assembly

   1. Assemble the following part:

      • Starter housing
      • Bearing retainer (Ex. 1.4 kW (Compact) Type)
      • Starter clutch
      • Compression spring
      • Clutch shaft

      

   2. Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar.

      

   3. Push down the starter housing, and install the following parts:

      • Spring retainer
      • Compression spring
      • Pinion gear
      • Stop collar

      

   4. Push down the pinion gear.

   5. Using snap ring pliers, install a new snap ring.

      

   6. Using pliers, compress the snap ring.

   7. Check that the snap ring fits correctly.

      

   8. Remove the starter housing and clutch assembly from the brass bar.

   9. Using a plastic-faced hammer, tap the clutch shaft and install the stop collar onto the snap ring.

      

Bearings¶

1. Inspect bearings.

   Turn each bearing by hand while applying inward force.

   If resistance is felt or if the bearing sticks, replace the bearing.

   

2. If necessary, replace bearings.

   1. Using SST, remove the bearing.

      SST 09286-46011

      

   2. Using SST and a press, press in a new front bearing.

      SST

      • 09201-41020 for 1.4 kW (conventional) and 1.6 kW types
      • 09285-76010 for 1.0 kW type
      • 09820-00030 for 1.4 kW (compact) type

   3. Using a press, press in a new rear bearing.

      

Magnetic switch¶

1. Perform pull-in coil open circuit test.

   Using an ohmmeter, check that there is continuity between terminals 50 and C.

   If there is no continuity, replace the magnetic switch.

   

2. Perform hold-in coil open circuit test.

   Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.

   If there is no continuity, replace the magnetic switch.

   

Assembly of starter¶

(See Removal of starter)

1. Place armature into field frame.

   Apply grease to the armature bearings, and insert the armature into the field frame.

   

2. Install brush holder.

   1. Place the brush holder in position on the armature.

   2. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the four brushes.

      Notice

      Check that positive (+) lead wires are not grounded.

      

   3. (1.4 kW and 1.6 kW Types)
      Place a new O-ring in position on the field frame.

      

   4. Install the end cover with two new O-rings (1.4 kW and 1.6 kW types) and the two screws.

      

3. Insert steel ball into clutch shaft hole.

   1. Apply grease to the steel ball.
   2. Insert the steel ball into the clutch shaft hole.

   

4. Install gear(s).

   1. Apply grease to the return spring.

   2. Insert the return spring into the magnetic switch hole.

      

   3. Place the following parts in position on the starter housing:

      (1.0 kW and 1.4 kW (Compact) Types)

      • Idler gear
      • Bearing

      

      (1.4 kW (Conventional) and 1.6 kW Types)

      • Idler gear
      • Bearing
      • Pinion gear

      

   4. Assemble the starter housing and magnetic switch with the two screws.

      

5. Install field frame and armature assembly.

   1. (1.4 kW and 1.6 kW Types)
      Place a new O-ring in position on the field frame.

      

   2. Align the protrusion of the field frame with the cutout of the magnetic switch.

      

      

      

   3. Install the field frame and armature assembly with the two through bolts.

      

   4. Connect the lead wire to terminal C, and install the nut.

Performance test of starter¶

1. Perform pull-in test.

   1. Disconnect the field coil lead wire from terminal C.
   2. Connect battery to the magnetic switch as shown. Check that the pinion gear moves outward.

   If the pinion gear does not move, replace the magnetic switch.

   

2. Perform hold-in test.

   While connected as above with the pinion gear out, disconnect the negative (–) lead from terminal C. Check that the pinion gear remains out.

   If the pinion gear returns inward, replace the magnetic switch.

   

3. Inspect plunger return.

   Disconnect the negative (–) lead from the switch body. Check that the pinion gear returns inward.

   If the pinion gear does not return, replace the magnetic switch.

   

4. Perform no-load performance test.

   1. Connect battery and ammeter to the starter as shown.
   2. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the reading on the ammeter.

   Standard amperage: 90 A or less at 11.5 V

   

Installation of starter¶

(See Removal of starter)

1. Install starter.

   1. Install the starter with the two bolts.

      Torque: 400 kg-cm (29 ft-lb, 39 N·m)

   2. Connect the starter connector.

   3. Connect the starter wire with the nut.
   4. Connect the starter cable with the nut.
   5. Install the terminal cover.

   

2. Install air cleaner.

   • 3S-GTE (See Cylinder block (5S-FE) › Inspection of piston and connecting rod assemblies, step 40)
   • 5S-FE (See Cylinder block (5S-FE) › Installation of engine, step 35)

3. Install LH engine hood side panel.

4. Connect cable to negative terminal of battery.
5. Check that engine starts.