ST0019
P13481
Ohmmeter
No Continuity
P02612
Lock
Free
− STARTINGSTARTER
ST−9
1996 RAV4 (RM447U)
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
1.2 kw type13.7 − 19.6 N (1.39 − 1.99 kgf, 3.06 − 4.38 lbf)
1.4 kw type17.6 − 23.5 N (1.79 − 2.39 kgf, 3.94 − 5.36 lbf)
Minimum spring installed load:
1.2 kw type9.8 N (0.99 kgf, 2.20 lbf)
1.4 kw type11.8 N (1.20 kgf, 2.65 lbf)
If the installed load is not within specification, replace the brush
springs.
11. 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.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.
13. INSPECT CLUTCH PINION GEAR
Hold the starter clutch and rotate the pinion gear counterclock-
wise, and check that it turns freely. Try to rotate the pinion gear
clockwise and check that it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
S00254
40 mm
Contact Plate 20 mm
37 mmWooden
Block
(kgf/cm2) =Ram diameter (cm)
100 kgf
2x 3.14 (π)
2
(psi) =Ram diameter (in.)
221 lbf
2x 3.14 (π)
2
(kPa) = (kgf/cm2) x 98.1
(kPa) = (psi) x 6.9
P25832
SST
P25833
ST−16
− STARTINGSTARTER
1996 RAV4 (RM447U)
8. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
9. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
10. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket and end cover with the 3 bolts.
Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf)
