1 INDEX STARTER 22-1 22-114E-03 CHAPTER 22 STARTER TROUBLESHOOTING...22-2 STARTER...22-4 22
22-2 STARTER 1 page 1 TROUBLESHOOTING Symptom Possible cause Remedy Engine does not crank, or cranks slowly Key switch Poor contact...polish or replace contacts Battery Discharged battery...charge Short circuited between electrodes... Replace battery Poor contact at battery terminal...polish or retighten Engine oil Improper viscosity oil...change oil Magnetic switch Poor contact caused by burnt...polish or replace contact plate contact plate Contact plate worn out...repair Hold-in coil disconnected...replace field coil (Overrunning clutch moves back and forth) Pull-in coil disconnected or...replace short circuited Starter relay Defective or poor contact...repair or replace Starter Brush worn out...replace Commutator burnt out...correct on lathe Commutator worn out...correct by undercutting Field winding shorted or grounded... Rewind or replace Armature winding shorted or grounded... Replace armature Insufficient brush spring tension...replace brush spring Poor contact between magnetic switch... Repair and field windings Armature contacts pole core because... Replace bearing brush or armature of worn bearing bush or bent armature shaft Overrunning clutch mulfunction...replace
1 page 1 STARTER 22-3 Symptom Possible cause Remedy Engine does not crank while starter is running in good condition Starter does not stop running Overrunning clutch Overrunning clutch mulfunction...replace Pinion teeth worn out...replace Poor sliding of spline teeth...remove foreign materials, dirt, or replace Key switch Contacts keep closing...replace Key switch sticks...replace Overrunning clutch sticks to armature... Repair or replace overrunning clutch or armature Starter relay Contacts keep closing...repair or replace
22-4 STARTER 1 page 1 STARTER 4 6 7 8 3 1 2 5 9 12 10 11 18 17 14 15 16 13 SM22-J101 1. Starter end frame 2. O-Ring 3. Yoke 4. O-Ring 5. Rear bearing 6. Armature 7. Front bearing 8. Brush holder 9. Brush 10. Roller 11. Idle gear 12. Drive gear 13. Magnetic switch 14. Return spring 15. Steel ball 16. Overrunning clutch 17. Starter housing 18. Retainer Fig. 1
1 page 1 STARTER 22-5 DISASSEMBLY 1. REMOVAL OF THE YOKE WITH ARMATURE 1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Fig. 2 SM22-J102 2. Remove the two through bolts. Fig. 3 FRONT O-RING SM22-J103 3. Pull out yoke with the armature. NOTE : Applying matchmarks to the yoke and starter housing before removing the yoke will make it easier to reinstall the yoke. 4. Remove the front O-ring from the yoke. Fig. 4 MATCHMARKS SM22-J104 2. REMOVAL OF BRUSHES AND BRUSH HOLDER 1. Remove the four screws. Fig. 5 SM22-J105 2. Using a screwdriver, hold the spring back and disconnect the brush from the holder. 3. Disconnect the four brushes and remove the brush holder. Fig. 6 SM22-J106
22-6 STARTER 1 page 1 NOTE : The brushes differ for the positive (+) and negative ( ) sides. When you reinstall them, make sure that you install them on the correct side. (+) SIDE BRUSH ( ) SIDE BRUSH SM22-J107 Fig. 7 MATCHMARKS REAR O-RING 3. REMOVE THE YOKE AND ARMATURE FROM THE STARTER END FRAME. 1. Remove the yoke from the starter end frame. NOTE : Applying matchmarks to the yoke and starter end frame before removing the yoke will make it easier to reinstall the yoke. 2. Remove the rear O-ring from the yoke. Fig. 8 SM22-J108 3. Using a plastic hammer, tap the frame end to remove the armature from the starter end frame. PLASTIC HAMMER Fig. 9 SM22-J109 4. REMOVAL OF THE MAGNETIC SWITCH 1. Remove the three mounting screws. SM22-J110 Fig. 10 r e t w y q SM22-J111 2. Remove the following parts from the magnetic switch: q Starter housing w Return spring e Drive gear r Retainer and rollers t Idle gear y Overrunning clutch Fig. 11
1 page 1 STARTER 22-7 MAGNETIC FINGER 3. Using a magnetic finger, remove the steel ball from the clutch shaft hole. SM22-J112 Fig. 12 OHMMETER CONTINUITY SM22-J113 INSPECTION AND REPAIR Armature Coil 1. INSPECT COMMUTATOR FOR OPEN CIRCUIT. Using an ohmmeter, check that there is continuity between the segments of the commutator. Inspection standard: Continuity exists. If there is no continuity between any segment, replace the armature. Fig. 13 OHMMETER NO CONTINUITY 2. INSPECT COMMUTATOR FOR GROUND. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. Inspection standard: No continuity. If there is continuity, replace the armature. SM22-J114 Fig. 14 HACKSAW BLADE 3. ARMATURE SHORT-CIRCUIT TEST. Using a growler tester, place the armature on it and hold a hacksaw blade against the armature core while slowly rotating the armature. Inspection standard: Hacksaw blade is not drawn in and does not vibrate. Fig. 15 GROWLER TESTER SM22-J115 WARNING Remove all foreign matter from the armature surface before doing the test.
22-8 STARTER 1 page 1 Fig. 16 SM22-J116 Commutator 1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or on a lathe. 2. INSPECT COMMUTATOR CIRCLE RUN-OUT. 1. Place the commutator on V-blocks. 2. Using a dial gauge, measure the circle run-out. Maximum circle run-out: 0.05 mm (0.0020 inch). If the circle run-out is greater than maximum, correct it on a lathe. Fig. 17 SM22-J117 3. INSPECT COMMUTATOR DIAMETER. Using a vernier caliper, measure the commutator diameter. Standard diameter: 36.0 mm (1.417 inch) for Model J05C-TD 43.0 mm (1.693 inch) for Model J08C-TP,TR Minimum diameter: 35.0 mm (1.378 inch) for Model J05C-TD 42.0 mm (1.654 inch) for Model J08C-TP,TR If the diameter is less than minimum, replace the armature. UNDERCUT DEPTH 4. INSPECT UNDERCUT DEPTH. Check that the undercut depth is clean and free off foreign materials. Smooth out the edge. Standard undercut depth: 0.7 mm (0.028 inch) to 0.9 mm (0.035 inch) Fig. 18 CONTINUITY SM22-J118 OHMMETER YOKE 1. INSPECT YOKE FOR OPEN CIRCUIT. Using an ohmmeter, check that there is continuity between the field coil end and the lead wire. Inspection standard: Continuity exists. If there is no continuity, replace the yoke. Fig. 19 SM22-J119
1 page 1 STARTER 22-9 NO CONTINUITY OHMMETER 2. INSPECT YOKE FOR GROUND. Using an ohmmeter, check that there is no continuity between the field coil end and yoke outside. Inspection standard: No continuity. If there is continuity, replace the yoke. SM22-J120 Fig. 20 Fig. 21 LENGTH SM22-J121 SM22-J122 BRUSHES 1. INSPECT CONTACT SURFACE OF BRUSH. If the contact surface is rough, correct it with sandpaper (No. 400). 2. INSPECT BRUSH LENGTH. Using a vernier caliper, measure the brush length. Standard length: 20.0 mm (0.787 inch) for Model J05C-TD 21.0 mm (0.827 inch) for Model J08C-TP,TR Minimum length: 13.0 mm (0.512 inch) for Model J05C-TD 14.0 mm (0.551 inch) for Model J08C-TP,TR If the length is less than minimum, replace the brush. NOTE : Measure the brush length at the center (indented) part. If replacing the brush, correct the contact surface of the new brush with sandpaper (No. 400) before installing it. BRUSH SPRINGS 1. INSPECT BRUSH SPRING LOAD. Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load: 3,500-4,500 g (123.5-158.7 oz) If the installed load is not within specification, replace the brush springs. Fig. 22 Fig. 23 NO CONTINUITY w q OHMMETER SM22-J123 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 holders. NOTE : Do the inspection at locations q and w shown in the illustration.
22-10 STARTER 1 page 1 LOCK FREE CLUTCH 1. 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. SM22-J124 Fig. 24 BEARINGS 1. INSPECT FRONT BEARING. Turn each bearing by hand while applying inward force. If the bearing sticks or does not rotate smoothly, replace the bearing. SM22-J125 Fig. 25 BEARING 2. IF NECESSARY, REPLACE FRONT BEARING. 1. Using a bearing puller, remove the bearing. BEARING PULLER SM22-J126 Fig. 26 Ø = 15 ~ 20 2. Using a press and a spacer, press in a new bearing. L = 30 TO 50 MM SPACER BEARING PRESS WARNING Do not use a spacer with an internal diameter greater than 20 mm. Using a larger spacer may cause damage to the bearing. Fig. 27 BASE SM22-J127 NOTE : Use a spacer of the size shown in Fig. 27. For example, a 17 mm (0.669 inch) socket wrench is suitable. Make sure that the base of press is stabilized and flat.
1 page 1 STARTER 22-11 3. INSPECT REAR BEARING. Turn each bearing by hand while applying inward force. If the bearing sticks, replace the bearing. SM22-J128 Fig. 28 BEARING BEARING PULLER 4. IF NECESSARY, REPLACE REAR BEARING. 1. Using a bearing puller, remove the bearing. SM22-J129 Fig. 29 UPWARD 2. Using a press, press in a new bearing. NOTE : Be careful to check the bearing installation direction. DOWNWARD SM22-J130 Fig. 30 TERMINAL C CONTINUITY OHMMETER MAGNETIC SWITCH 1. INSPECT PULL-IN COIL FOR OPEN CIRCUIT. Using an ohmmeter, check that there is continuity between terminals 50 and C. Inspection standard: Continuity exists. If there is no continuity, replace the magnetic switch. TERMINAL 50 SM22-J131 Fig. 31 CONTINUITY OHMMETER 2. INSPECT HOLD-IN COIL FOR OPEN CIRCUIT. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. Inspection standard: Continuity exists. If there is no continuity, replace the magnetic switch. TERMINAL 50 SM22-J132 Fig. 32
22-12 STARTER 1 page 1 TERMINAL C Fig. 33 TERMINAL 50 TERMINAL M. T SM22-J133 MAGNETIC SWITCH TEST The following tests should be performed without the armature assembly. NOTE : Each test should be performed for a short time (3 to 5 sec. ) to prevent the magnetic switch winding from burning. Each test should be performed with the specified voltage applied. 1. PULL-IN TEST Connect the test leads as shown in Fig. 33. When connecting terminal C and M. T are closed, the pinion should jump out. 2. HOLD-IN TEST With the same condition as in the pull-in test, open the connecting terminal C. The pinion should remain in the jumped out position. TERMINAL C TERMINAL M. T TERMINAL 50 SM22-J134 Fig. 34 TERMINAL C 3. RETURN TEST With the same condition as in the hold-in test, open the connecting terminal 50. The pinion should return immediately. TERMINAL 50 TERMINAL M. T SM22-J135 Fig. 35
1 page 1 STARTER 22-13 Fig. 36 q r e w t u i y o SM22-J154 ASSEMBLY Reverse the order of disassembly to reassemble the starter. However, attention should be paid to the following operations. 1. LUBRICATION Before reassembling, apply the recommended grease to the following: [Apply Nippondenso No. 50 grease or equivalent (Esso beacon 325)]. q Rear bearing w Front bearing e Roller r Retainer t Idle gear y Drive gear u Return spring i Steel ball o Overrunning clutch 2. INSTALLATION OF ARMATURE NOTE : Use high-temperature grease to lubricate the bearings and gears when assembling the starter. Apply grease to the armature bearings, and using a press, press the armature into the starter end frame. SM22-J136 Fig. 37 WARNING Rotate the starter end frame and check that the armature is pressed straight into it. If the armature is pressed in crookedly, it will later make it difficult to assemble the starter housing. SM22-J137 Fig. 38 MATCHMARKS 3. INSTALLATION OF YOKE 1. Install a new O-ring to groove of the yoke. 2. While matching the matchmarks, install the yoke and starter end frame. REAR O-RING Fig. 39 SM22-J138
22-14 STARTER 1 page 1 CLAW 4. INSTALLATION OF BRUSHES 1. Align the claw of the brush holder with the claw groove of the yoke. 2. Place the brush holder onto the yoke. CLAW GROOVE Fig. 40 SM22-J139 3. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the four brushes. Fig. 41 SM22-J140 4. Install the lead wires with the four screws. NOTE : Check that the positive (+) lead wires are not grounded. Take care not to damage them or get oil on them. Fig. 42 SM22-J141 5. INSTALLATION OF MAGNETIC SWITCH 1. Apply grease to the steel ball. 2. Insert the steel ball into the overrunning clutch shaft hole. Fig. 43 SM22-J142 3. Apply grease to the return spring. 4. Insert the return spring into the magnetic switch hole. Fig. 44 SM22-J143
1 page 1 STARTER 22-15 e r w 5. Place the following parts in position on the starter housing: q Overrunning clutch w Idle gear e Retainer and rollers r Drive gear q Fig. 45 SM22-J144 6. Assemble the starter housing and magnetic switch assembly and install the three screws. Fig. 46 SM22-J145 6. INSTALLATION OF YOKE AND ARMATURE 1. Place a new front O-ring in position on the yoke. NEW FRONT O-RING Fig. 47 SM22-J146 2. Match up the matchmarks on the yoke and starter housing. MATCHMARK SM22-J147 Fig. 48 3. Install the yoke and armature assembly with the two through bolts. Tightening torque: 110-180 kg cm (8.0-13 lb ft) SM22-J148 Fig. 49
22-16 STARTER 1 page 1 4. Connect the lead wire to terminal C, and install the nut. Tightening torque: 180-250 kg cm (13-18 lb ft) Fig. 50 TERMINAL C TERMINAL 50 Fig. 51 TERMINAL C BATTERY SM22-J149 SM22-J150 PERFORMANCE TEST OF STARTER NOTE : These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. PERFORM PULL-IN TEST. 1. Disconnect the field coil lead wire from terminal C. 2. Connect battery to the magnetic switch as shown. 3. Check that the pinion gear moves outward. If the pinion gear does not move, replace the magnetic switch. 2. PERFORMANCE HOLD-IN TEST 1. While connected as above with the pinion gear out, disconnect the negative ( ) lead from terminal C. 2. Check that the pinion gear remains out. If the pinion gear returns inward, replace the magnetic switch. BATTERY SM22-J151 Fig. 52 3. INSPECT PLUNGER RETURN. (Solenoid Coil Balance Check) 1. Disconnect the positive (+) lead from terminal 50. 2. Check that the pinion gear returns inward. If the pinion gear does not return, replace the magnetic switch. TERMINAL 50 BATTERY SM22-J152 Fig. 53 AMMETER TERMINAL M.T TERMINAL 50 BATTERY SM22-J153 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: 220 A or less/12v 120 A or less/24v Fig. 54
1 page 1 STARTER 22-17 DIAGNOSIS AND TESTING FOR STARTING SYSTEM Use the diagnostic charts below when you check the starting system. Before diagnosis, be sure the battery is fully charged and inspect the starter and battery cables for clean and tight connections. CAUTION 1. Do not operate the starter longer than 30 seconds. 2. Do not disconnect or short any lead wire while starter is operating. DIAGNOSTIC CHART IG switch START position Engine does not start Engine starts, but pinion does not disengage Starter does not crank engine Starter cranks engine, but very slowly Go to diagnosis 1 Go to diagnosis 2 Go to diagnosis 3
22-18 STARTER 1 page 1 Diagnosis 1 Turn IG switch to START position Does magnetic switch click? OK NG Perform test 2 (on page 19) Perform test 1 (on page 19) NG NG OK OK Remove starter from engine and repair it Replace magnetic switch Repair or replace the key switch, relay and wiring Replace magnetic switch Diagnosis 2 OK Check starting system circuit NG Is battery in good condition? OK NG Remove starter and repair Recharge or replace battery Clean and retighten cable and wire Diagnosis 3 Check the operation of starting switch and relay OK NG Remove starter and repair Repair or replace if necessary
1 page 1 STARTER 22-19 ORIGINAL WIRING HARNESS (TO STARTER RELAY OR KEY IG SWITCH) JUMPER WIRE ORIGINAL WIRING HARNESS (TO BATTERY) M.T DISCONNECTED LEAD WIRE 50 TEST 1 1. Disconnect the cable from C terminal. 2. Connect a jumper wire to positive terminal of battery. 3. Briefly touch "50" terminal of magnetic switch with the jump wire. 4. If the magnetic switch operates, probable cause of starter failure is in the wiring, starting switch or relay. BATTERY STARTER Fig. 55 DISCONNECTED LEAD WIRE CIRCUIT TESTER M.T C SM22-J154 50 TEST 2 1. Disconnect the cables from C, M.T and 50 terminal. 2. Using an ohmmeter, touch the 50 terminal with one probe and the starter body with the other. There should be continuity. 3. If there is no continuity, the hold-in winding is opencircuited. Replace the magnetic switch if opencircuited. TO GROUND STARTER Fig. 56 SM22-J155 DISCRIMINATION OF STARTER TERMINALS Each terminal can be discriminated as follows: M.T... Main terminal to which the main cable from battery is connected. C... C-terminal to which the lead wire from the yoke is connected. 50... 50-terminal to which the lead wire from the starting switch or starter relay is connected.