Page 2889 of 4323
B13806
P10568
± STARTINGSTARTER
ST±7
2881 Author: Date:
2005 SEQUOIA (RM1146U)
4. REMOVE BRUSH HOLDER
(a) Remove the 2 screws w/ O±ring and the end cover from
the field frame.
Torque: 3.8 N´m (39 kgf´cm, 34 in.´lbf)
(b) Remove the O±ring from the field frame.
HINT:
At the time of assembly, use a new O±ring.
(c) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the 4
brushes, and remove the brush holder.
NOTICE:
Check that the positive (+) lead wires are not grounded.
5. REMOVE ARMATURE FROM FIELD FRAME
Page 2890 of 4323

ST0N3±04
S00054
Ohmmeter
Continuity
S00055
Ohmmeter No Continuity
S00056
S00057
ST0040
ST±8
± STARTINGSTARTER
2882 Author: Date:
2005 SEQUOIA (RM1146U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V±blocks.
(b) Using a dial indicator, 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.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
35.0 mm (1.378 in.)
Minimum diameter:
34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth:
0.7 mm (0.028 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.
Page 2891 of 4323

P10588
Ohmmeter
Continuity
P00299
OhmmeterContinuity
S02267
Ohmmeter(B)
(A)
Z00037
ST0019
± STARTINGSTARTER
ST±9
2883 Author: Date:
2005 SEQUOIA (RM1146U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
field coil end and field frame.
If there is no continuity, repair or replace the field frame.
9. INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt
coil terminals (A) and (B).
Resistance: 1.5 to 1.9 W at 20 °C (68 °F)
If the resistance is not as specified, replace the field frame.
10. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length: 15.0 mm (0.591 in. )
Minimum length: 9.0 mm (0.354 in. )
If the length is less than minimum, replace the brush holder and
field frame.
11. INSPECT BRUSH SPRING LOAD
Using a pull scale, measure the spring load by pulling the spring
from the brush until they are separated.
Standard spring installed load: 21.5 to 27.5 N ( 2.2 to
2.8 kgf, 4.8 to 6.2 lbf )
Minimum installed load: 12.7 N (1.3 kgf, 2.9 lbf )
If the installed load is less than minimum, replace the brush
springs.
Page 2892 of 4323

P21088
Ohmmeter
No Continuity
P10821
Free
Lock
B12319
Terminal CTerminal 50
ContinuityOhmmeter
B12320ContinuityOhmmeter
Terminal 50
ST±10
± STARTINGSTARTER
2884 Author: Date:
2005 SEQUOIA (RM1146U)
12. 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.
13. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If any damage is found, replace the gear or clutch assembly,
and also check the drive plate ring gear for wear or damage.
14. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Check that it locks by rotating the pinion gear counterclockwise.
If necessary, replace the clutch assembly.
15. INSPECT FRONT AND REAR BEARING
Turn the bearing by hand as applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL±IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, replace the magnetic switch.
17. DO HOLDING COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
Page 2893 of 4323
ST092±07
S00058
SST
S00059
S00060
SST
S00061
SST Upward
Downward
B12321
± STARTINGSTARTER
ST±11
2885 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286±46011
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820±00031
3. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the magnetic switch end cover.
Remove the 3 nuts, the end cover, the gasket and the
plunger.
NOTICE:
Do not loosen the 3 stud bolts.
Page 2894 of 4323

B12322
Wear
B12323
SST
B12324
(2)
(1)(3)
(5)
(4)
B12325
(2)
(3) (4) (5)(1)
ST±12
± STARTINGSTARTER
2886 Author: Date:
2005 SEQUOIA (RM1146U)
(b) Inspect contact plate for wear.
Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear:
0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove terminal kit parts.
(1) Put a wooden block on the plate, and press it down
with a hand press.
Dimensions of wooden block:
20 X 33 X 40 mm (0.79 X 1.30 X 1.57 in.)
(2) Using SST, loosen the terminal nuts.
SST 09810±38140
(3) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate and terminal insulator (inside).
(4) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O±ring, terminal bolt, contact
plate, terminal insulator (inside) and insulation pa-
per.
(d) Temporarily install these new terminal 30 kit parts:
(1) Contact plate
(2) Terminal bolt
(3) O±ring
(4) Wave washer
(5) Terminal nut
(e) Temporarily install these new terminal C kit parts:
(1) Contact plate
(2) Terminal bolt
(3) O±ring
(4) Wave washer
(5) Terminal nut
(f) Temporarily tighten the terminal nuts.
Page 2895 of 4323

B12323
33 mm20 mm
Contact
Plate
40 mm
(kgf/cm2)
(psi)
(kPa) = (psi) x 6.9100 kgf
2 Ram diameter (cm)
(kPa) = (kgf/cm
2) x 98.1 ==
x 3.14 (p)
2
221lbf
2 Ram diameter (in.)
x 3.14 (p)
2
B13044
SST
B12326
± STARTINGSTARTER
ST±13
2887 Author: Date:
2005 SEQUOIA (RM1146U)
(g) Tighten terminal nuts.
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 33 x 40 mm (0.79 x 1.30 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.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810±38140
Torque: 17 N´m (170 kgf´cm, 13 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the plas-
tic frame.
(h) Clean contact surfaces of the contact plate and the plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the magnetic switch end cover.
Install the plunger, the new gasket and the end cover with
the 3 nuts.
Torque: 3.6 N´m (37 kgf´cm, 32 in.´lbf)
Page 2896 of 4323
ST093±03
ST±14
± STARTINGSTARTER
2888 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST±6).
HINT:
At the time of assembly, use high±temperature grease to lubricate the bearing and gears when assembling
the starter.