1999 SUBARU FORESTER Service Repair Manual

3) Lock test
With starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage / Current
MT vehicles
4 V/780 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
15.7 N´m (1.60 kg-m, 11.6 ft-lb) or more
AT vehicles
28.9 N´m (2.95 kg-m, 21.3 ft-lb) or more
C: DISASSEMBLY
1. STARTER ASSEMBLY
1) Loosen nut which holds terminal M of switch
assembly, and disconnect connector.
2) Remove bolts which hold switch assembly, and
remove switch assembly, plunger and plunger
spring from starter as a unit.
CAUTION:
Be careful because pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
S6M0396A
(A) Switch ASSY
(B) Plunger
3) Remove both through-bolts and brush holder
screws, and detach rear bracket and brush holder.
H6M0494C
(A) Brush holder
(B) Rear bracket
4) Remove armature and yoke. Ball used as a
bearing will then be removed from the end of arma-
ture.
CAUTION:
Be sure to mark an alignment mark on yoke
and front bracket before removing yoke.
H6M0495C
(A) Front bracket
(B) Yoke
(C) Ball
(D) Armature
8
6-1[W1C1]SERVICE PROCEDURE
1. Starter

5) Remove packing A, three planetary gears,
packing B and plate.
CAUTION:
Record the position of packing A before remov-
ing.
S6M0397A
(A) Packing A
(B) Planetary gear
(C) Plate
(D) Packing B
6) Remove shaft assembly and overrunning clutch
as a unit.
CAUTION:
Record the direction of lever before removing.
S6M0398A
(A) Shaft ASSY
(B) Overrunning clutch
(C) Lever
7) Remove overrunning clutch from shaft assem-
bly as follows:
(1) Remove stopper from ring by lightly tapping
a fit tool placed on stopper.
(2) Remove ring, stopper and clutch from shaft.
S6M0399A
(A) Stopper
(B) Tool
(C) Ring
(D) Shaft
2. BRUSH HOLDER
Slightly open the metal fitting holding the insulating
plate to the brush holder. Remove the insulating
plate.
NOTE:
The brush and spring can be easily removed from
the brush holder at this time.
H6M0497C
(A) Brush holder
(B) Insulating plate
(C) Metal fitting
D: INSPECTION
1. ARMATURE
1) Check commutator for any sign of burns of
rough surfaces or stepped wear. If wear is of a
minor nature, correct it by using sand paper.
9
[W1D1]6-1SERVICE PROCEDURE
1. Starter

2) Run-out test
Check the commutator run-out and replace if it
exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
S6M0400A
(A) V-block
3) Depth of segment mold
Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
S6M0401A
(A) Depth of mold
(B) Segment
(C) Mold
4) Armature short-circuit test
Check armature for short-circuit by placing it on
growler tester. Hold a hacksaw blade against
armature core while slowly rotating armature. A
short-circuited armature will cause the blade to
vibrate and to be attracted to core. If the hacksaw
blade is attracted or vibrates, the armature, which
is short-circuited, must be replaced or repaired.
S6M0402A
(A) Iron sheet
(B) Growler tester
5) Armature ground test
Using circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is a continuity,
armature is grounded.
Replace armature if it is grounded.
G6M0041
10
6-1[W1D1]SERVICE PROCEDURE
1. Starter

2. YOKE
Make sure pole is set in position.
3. OVERRUNNING CLUTCH
Inspect teeth of pinion for wear and damage.
Replace if it is damaged. Rotate pinion in direction
of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length and replace if it exceeds
the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
H6M0496C
(A) Service limit line
(B) Brush
2) Brush movement
Be sure brush moves smoothly inside brush
holder.
3) Brush spring force
Measure brush spring force with a spring scale. If
it is less than the service limit, replace brush
holder.
Brush spring force:
Standard
21.6 N (2.2 kg, 4.9 lb) (when new)
Service limit
5.9 N (0.6 kg, 1.3 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between terminals S
and M, and between terminal S and ground. Use
a circuit tester (set in ªohmº).
Also check to be sure there is no continuity
between terminal M and B.
Terminal / Specified resistance:
SÐM/Continuity
S Ð Ground / Continuity
MÐB/Nocontinuity
S6M0403
E: ASSEMBLY
Assemble in the reverse order of disassembly. Do
the following:
1) Carefully assemble all parts in the order of
assembly and occasionally inspect nothing has
been overlooked.
2) Apply grease to the following parts during
assembly.
IFront and rear bracket sleeve bearing
IArmature shaft gear
IOuter periphery of plunger
IMating surface of plunger and lever
IGear shaft splines
IMating surface of lever and clutch
IBall at the armature shaft end
IInternal and planetary gears
3) After assembling parts correctly, check to be
sure starter operates properly.
11
[W1E0]6-1SERVICE PROCEDURE
1. Starter

2. Generator
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G6M0095
2) Disconnect connector and terminal from gen-
erator.
S2M0941
3) Remove V-belt cover.
S2M0896
4) Remove front side V-belt.
G2M0286
5) Remove bolts which install generator onto
bracket.
S2M0942
6) Install in the reverse order of removal.
CAUTION:
Check and adjust V-belt tension. [G2A0].>
S2M0942
B: DISASSEMBLY
1) Remove the four through bolts. Then insert the
tip of a flat-head screwdriver into the gap between
the stator core and front bracket. Pry then apart to
disassemble.
S6M0404
12
6-1[W2A0]SERVICE PROCEDURE
2. Generator

2) Hold rotor with a vise and remove pulley nut.
G6M0066
CAUTION:
When holding rotor with vise, insert aluminum
plates or wood pieces on the contact surfaces
of the vise to prevent rotor from damage.
H6M0498C
(A) Front bracket
(B) Pulley
(C) Nut
(D) Rotor
3) Unsolder connection between rectifier and sta-
tor coil to remove stator coil.
CAUTION:
Finish the work rapidly (less than three sec-
onds) because the rectifier cannot withstand
heat very well.
G6M0068
4) Remove screws which secure IC regulator to
rear cover, and unsolder connection between IC
regulator and rectifier to remove IC regulator.
G6M0069
5) Remove the brushes by unsoldering at the pig-
tails.
G6M0070
6) Remove the nut and insulating bushing at ter-
minal B, and remove rectifier.
S6M0405A
(A) Rectifier
(B) Rear cover
(C) Nut
C: INSPECTION AND REPAIR
1. DIODE
CAUTION:
Never use a megger tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be dam-
aged.
13
[W2C1]6-1SERVICE PROCEDURE
2. Generator

1) Checking positive diode
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity exists only in the direc-
tion from the diode lead to the heat sink.
S6M0406A
(A) Diode lead
(B) Heat sink (Positive side)
2) Checking negative diode
Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if continuity exists only in the direc-
tion from the heat sink to the diode lead.
S6M0407A
(A) Diode lead
(B) Heat sink (Negative side)
2. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any rough-
ness of the sliding surface. Repair slip ring surface
using a lathe or sand paper.
2) Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check resistance between slip rings using circuit
tester.
If the resistance is not within specification, replace
rotor assembly.
Specified resistance:
Approx. 2.7 Ð 3.2
W
G6M0075
4) Insulation test
Check continuity between slip ring and rotor core
or shaft. If continuity exists, the rotor coil is
grounded, and so replace rotor assembly.
G6M0076
5) Ball bearing (rear side)
(1) Check rear ball bearing. Replace if it is
noisy or if rotor does not turn smoothly.
(2) The rear bearing can be removed by using
common bearing puller.
G6M0077
14
6-1[W2C2]SERVICE PROCEDURE
2. Generator

3. STATOR
1) Continuity test
Inspect stator coil for continuity between each end
of the lead wires. If there is no continuity between
individual lead wires, the lead wire is broken, and
so replace stator assembly.
S6M0408
2) Insulation test
Inspect stator coil for continuity between stator
core and each end of the lead wire. If there is
continuity, the stator coil is grounded, and so
replace stator assembly.
G6M0079
4. BRUSH
1) Measure the length of each brush. If wear
exceeds the service limit, replace the brush. Each
brush has the service limit mark (A) on it.
Brush length:
Standard
18.5 mm (0.728 in)
Service limit
5.0 mm (0.197 in)
H6M0499C
2) Checking brush spring for proper pressure
Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of the brush
spring. If the pressure is less than 2.648 N (270 g,
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).
G6M0143
5. BEARING (FRONT SIDE)
1) Check front ball bearing. If resistance is felt
while rotating, or if abnormal noise is heard,
replace the ball bearing.
2) Replacing front bearing
(1) Remove front bearing retainer.
(2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front
bracket with a hand press or vise. A socket
wrench can serve as the tool.
S6M0409A
(A) Front bracket
(B) Socket wrench
15
[W2C5]6-1SERVICE PROCEDURE
2. Generator