Page 1617 of 2890
2. AT: 128000-8321
B6M0413A
1Front ball bearing
2Armature
3Rear ball bearing
4O-ring
5Yoke
6Brush spring
7Brush holder
8End frame
9Cover
10Screw & washer
11Through bolt
12Screw & washer
13Starter housing
14Overrunning clutch
15Steel ball
16Spring
17Retainer
18Roller
19Idle gear
20Nut
21Spring washer
22Magnet switch
23Nut
4
6-1COMPONENT PARTS
1. Starter
Page 1618 of 2890
2. Generator
B6M0414A
1Pulley nut
2Pulley
3Front cover ASSY
4Ball bearing
5Bearing retainer
6Screw
7Rotor
8Stator coil
9IC regulator ASSY
10Condenser
11Diode ASSY
12Bolt
13Bolt
14Brush holder ASSY
15Rear cover
16BAT. terminal
17Nut
18Bolt
19Through bolt
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.1 — 4.4 (0.32 — 0.45, 2.3 — 3.3)
T2: 63.7 — 83.4 (6.5 — 8.5, 47.0 — 61.5)
5
6-1COMPONENT PARTS
2. Generator
Page 1619 of 2890
G6M0095
1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0309
2) Disconnect connector and terminal from starter.
3) Remove starter from transmission.
4) Installation is in the reverse order of removal.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B: TEST
1. MAGNETIC SWITCH
CAUTION:
The following magnetic switch tests should be per-
formed with specified voltage applied.
Each test should be conducted within 3 to 5 sec-
onds. Power to be furnished should be one-half the
rated voltage.
B6M0415A
1) Pull-in test
Connect two battery negative leads onto magnetic switch
body and terminal C respectively. Then connect battery
positive lead onto terminal 50. Pinion should extend when
lead connections are made.
B6M0416A
2) Holding-in test
Disconnect lead from terminal C with pinion extended. Pin-
ion should be held in the extended position.
6
6-1SERVICE PROCEDURE
1. Starter
Page 1620 of 2890

B6M0417A
3) Return test
Connect two battery negative leads onto terminal 50 and
onto switch body respectively. Then connect battery posi-
tive lead onto terminal C. Next, disconnect lead from ter-
minal 50. Pinion should return immediately.
2. PERFORMANCE TEST
The starter is required to produce a large torque and high
rotating speed, but these starter characteristics vary with
the capacity of the battery. It is therefore important to use
a battery with the specified capacity whenever testing the
starter.
The starter should be checked for the following three items:
1. No-load test
Measure the maximum rotating speed and current under a
no-load state.
2. Load test
Measure the magnitude of current needed to generate the
specified torque and rotating speed.
3. Stall test
Measure the torque and current when the armature is
locked.
B6M0418A
1) No-load test
Run single starter under no-load state, and measure its
rotating speed, voltage, and current, using the specified
battery. Measured values must meet the following stan-
dards:
No-load test (Standard):
Voltage/Current
11 V/90 A, or more
Rotating speed
TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
7
6-1SERVICE PROCEDURE
1. Starter
Page 1621 of 2890

B6M0419A
2) Load test (For reference)
Perform this test to check maximum output of starter. Use
test bench which is able to apply load (brake) to starter.
Measure torque value and rotating speed under the speci-
fied voltage and current conditions while controlling brak-
ing force applied to starter.
CAUTION:
Change engagement position of overrunning clutch
and make sure it is not slipping.
Load test (Standard):
TN128000-8311
Voltage/Load
8 V/9.8 N⋅m (1.0 kg-m, 7.2 ft-lb)
Current/Speed
280 A max./900 rpm min.
TN128000-8321
Voltage/Load
8 V/13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
B6M0420A
3) Stall test
Using the same test equipment used for load test, apply
brake to lock starter armature. Then measure voltage,
current, and torque values.
Measured values must meet the following standard.
Stall test (Standard):
TN128000-8311
Voltage/Current
5 V/800 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Current
5 V/1,050 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
NOTE:
Low rotating speed or excessive current during no-load test
may be attributable to high rotating resistance of starter
due to improper assembling.
Small current and no torque during stall test may be attrib-
utable to excessive contact resistance between brush and
commutator; whereas, normal current and insufficient
torque may be attributable to shorted commutator or poor
insulation.
Starter can be considered normal if it passes no-load and
stall tests; therefore, load test may be omitted.
8
6-1SERVICE PROCEDURE
1. Starter
Page 1622 of 2890
B6M0421A
C: DISASSEMBLY
1) Disconnect lead wire from magnetic switch.
B6M0422A
2) Remove through-bolts from end frame.
B6M0423A
3) Remove yoke from magnetic switch.
B6M0424A
4) Remove screws securing end frame to brush holder.
B6M0425A
5) Separate yoke from end frame.
9
6-1SERVICE PROCEDURE
1. Starter
Page 1623 of 2890
B6M0426A
6) Remove brush by lifting up positive (+) side brush
spring using long-nose pliers.
CAUTION:
Be careful not to damage brush and commutator.
B6M0427A
7) Remove armature from yoke.
CAUTION:
Be careful not to drop armature.
B6M0428A
8) Remove screws securing magnetic switch to housing.
B6M0429A
9) Remove housing from magnetic switch.
B6M0430A
10) Remove clutch from housing.
10
6-1SERVICE PROCEDURE
1. Starter
Page 1624 of 2890
B6M0431A
11) Take out steel ball from clutch.
CAUTION:
Be careful not to lose steel ball.
B6M0432A
12) Remove idle gear from housing.
B6M0433A
13) Remove retainer and roller from housing.
CAUTION:
Be careful not to drop retainer and roller.
B6M0434A
14) Remove coil spring from magnetic switch.
D: INSPECTION
1. ARMATURE
1) Check commutator for any sign of burns of rough sur-
faces or stepped wear. If wear is of a minor nature, correct
it by using sand paper.
11
6-1SERVICE PROCEDURE
1. Starter