1996 TOYOTA TERCEL Service Repair Manual

ST083-07
ST0663
Continuity
ST0664No Continuity
Z03211
Z03209
ST0040
- STARTINGSTARTER (Planetary Type)
ST-19
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT ARMATURE COIL
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
(b) Check the commutator for ground.
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty and burnt surface.
If the surface is dirty or burn, correct with sandpaper (No.400)
or a lathe.
(d) Check for the commutator circle runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, 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.
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 28.0 mm (1.102 in.)
Minimum diameter: 27.0 mm (1.063 in.)
If the diameter is less than minimum, replace the armature.
(f) Check that the undercut depth is clean and free of foreign
materials. 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.

ST0666
Continuity
ST0665No Continuity
ST0648
ST0019
ST0660
No Continuity ST-20
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
2. INSPECT FIELD COIL
(a) Check the field coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
(b) Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.
3. INSPECT BRUSHES
Check the brush length.
Using vernier calipers, measure the brush length.
Standard length: 14.0 mm (0.551 in.)
Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush (field frame
side) or brush holder, and dress with an emery cloth.
4. INSPECT BRUSH SPRINGS
Check the brush spring load.
Take the pull scale reading the instant the brush spring
separates from the brush.
Spring installed load:
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
Minimum spring installed load:
8.8 N (0.9 kgf, 2.0 lbf)
If the installed load is not as specified, replace the brush
springs.
5. INSPECT BRUSH HOLDER
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.

ST0661
Free
Lock
ST0667
P25604
Terminal C
Continuity Terminal 50
P25605
Continuity Terminal 50 Switch
Body
- STARTINGSTARTER (Planetary Type)
ST-21
1996 TERCEL (RM440U)
6. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the planetary gear, internal gear
and starter clutch for wear or damage.
If the gear is damaged, replace it.
If the starter clutch teeth are damaged, replace the starter
clutch and also inspect the flywheel ring gear for wear or dam-
age.
(b) Check the starter clutch.
Rotate the clutch pinion gear clockwise and check that it
turns freely. Try to rotate the clutch pinion gear counter-
clockwise and check that it locks.
If necessary, replace the starter clutch.
7. INSPECT MAGNETIC SWITCH
(a) Check the plunger.
Push in the plunger and replace it. Check that it returns
quickly to its original position.
If necessary, replace the magnetic switch.
(b) Check the pull-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, replace the magnetic switch.
(c) Check the hold-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

ST0649
ST0650
ST-22
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
8. INSPECT BEARINGS
(a) Check the planet carrirer shaft.
Using a micrometer, measure the outer diameter of the
surface in contact with the center bearing of the planet
carrier shaft.
Standard shaft diameter:
14.035 - 15.000 mm (0.5526 - 0.5906 in.)
(b) Check the center bearing.
(1) Using a caliper gauge, measure the inside diameter
of the center bearing.
Center bearing inside diameter:
15.000 - 15.035 mm (0.5906 - 0.5919 in.)
(2) Subtract the planet carrier shaft diameter from the
bearing inside diameter measurement.
Standard center bearing oil clearance:
0.03 mm (0.0012 in.)
Maximum center bearing oil clearance:
0.1 mm (0.004 in.)
If the clearance is greater than maximum, replace the planet
carrier shaft and center bearing.

ST084-06
Z07247
York Side
Terminal
Served PartCut
York Side
Terminal
Served Part
Z07248
Width Thickness
Z07249
Weld Side
Z07250
3.3 mm
7 mm
Z03208
SST
- STARTINGSTARTER (Planetary Type)
ST-23
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE BRUSHES
HINT:
Only the 2 brushes of the positive (+) side (york side) are ex-
changeable, negative (-) side brush must be changed in the
body with the brush holder.
(a) Cut the brush lead wire at the terminal side.
(b) Shave welded mark of the brush lead wire with sandpaper
etc., and correct the terminal to the specified.
NOTICE:
Part to be shaved is so narrow that you should take care not
to harm the field coil.
Specified width: 5.0 mm (0.197 in.)
Specified thickness: 1.5 - 1.7 mm (0.059 - 0.067 in.)
(c) Press the plate of the supply brush on the welded side of
the terminal lead wire.
(d) Solder the pressed part, and shave to the specified mea-
sures with the sandpaper etc.
Specified width: 7.0 mm (0.276 in.)
Specified thickness: 3.3 mm (0.130 in.)

Heat the soldered part well, and fiow the solder in-
side the plate, take care not to flow it into flow it into
the inside lead wire.

Take care not to flow the solder into field.
2. REPLACE CENTER BEARING
(a) Using SST and press, press out the center bearing.
SST 09221-25026 (09221-00090)

ST0670
SST ST-24
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
(b) Using SST and a press in a new center bearing to the
position shown in the illustration.
SST 09221-25026 (09221-00090)

ST085-03
ST0646
Grease
ST0647
Hollow
Protrusion
ST0671
Planet Carrier Shaft
Plate Washer Shock Absorber
ST0672
ST0673
- STARTINGSTARTER (Planetary Type)
ST-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Use high temperature-resistant grease to lubricate the bear-
ings and sliding parts when assembling the starter.
1. INSTALL INTERNAL GEAR AND PLANET CARRIER
SHAFT
(a) Apply grease to the internal gear touching the shock ab-
sorber and planetary gears.
(b) Align the hollow of the internal gear with the protrusion in-
side the shock absorber.
(c) Insert and turn the internal gear so that it interlocks with
the shock absorber.
(d) Apply turbine oil to the center bearing.
(e) Apply grease to the plate washer, and install it to the plan-
et carrier shaft.
(f) Install the planet carrier shaft to the shock absorber.
(g) Using snap ring pliers, install the plate washer and snap
ring.
2. INSTALL STARTER CLUTCH
(a) Apply grease to the bushing and spline of the starter
clutch stop collar.
(b) Place the starter clutch and stop collar on the planet carri-
er shaft.
(c) Apply grease to the snap ring, and install it to the planet
carrier shaft groove.
(d) Using a vise, compress the snap ring.

ST0674
Z07229
Protrusion
Cutout
ST1086
ST1089
Cutout
Protrusion
ST0656
ST-26
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
(e) Hold the starter clutch, tap the planet carrier shaft and
install the stop collar onto the snap ring with a plastic-
faced hammer.
3. INSTALL PLANETARY GEARS
(a) Apply grease to the planetary gears and flange pin parts
of the planet carrier shaft.
(b) Install the plate washer and 3 planetary gears.
(c) Align the cutout of the plate with the protrusion inside the
shock absorber, and install the plate.
4. INSTALL DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER
(a) Apply turbine oil to the bearing of the starter drive hous-
ing.
(b) Apply grease to the drive lever touching the starter pivot
part of the drive lever.
(c) Install the drive lever to the starter clutch.
(d) Align the protrusion of the shock absorber with the cutout
of the drive housing and install them.
5. PLACE ARMATURE INTO FIELD FRAME
6. INSTALL BRUSH HOLDER
(a) Place the brush holder in position on the armature.
(b) Using a screwdriver, hold the brush spring back, and con-
nect the brush into the brush holder. Connect the 4
brushes.
NOTICE:
Check that positive (+) lead wires are not grounded.
(c) Install a new O-ring to the groove of the field frame.
(d) Apply turbine oil to the bearing of the end cover.