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Removal and InstallationEKS0031J
REMOVAL
M/T models
1. Disconnect negative battery cable.
2. Remove air duct. Refer toEM-15, "
AIR CLEANER AND AIR
DUCT"(QR engine models) orEM-112, "AIR CLEANER AND
AIR DUCT"(YD engine models).
3. Disconnect S terminal and B terminal from starter motor.
4. Remove starter motor mounting bolts.
5. Remove starter motor from upper side the vehicle.
A/T models
1. Disconnect negative battery cable.
2. Remove air duct and air cleaner assembly. Refer toEM-15, "
AIR
CLEANER AND AIR DUCT"(QR engine models) orEM-112,
"AIR CLEANER AND AIR DUCT"(YD engine models).
3. Remove A/T selector cable and harness from bracket.
4. Disconnect S terminal and B terminal from starter motor.
5. Remove starter motor from upper side the vehicle.
INSTALLATION
Install in the reverse order of removal.
QR20 engine models (M/T)
QR20 engine models (A/T)
YD22 engine models
PKIA0462E
PKIA0463E
Bterminalnut:
:9.81 - 11.8 N·m (1.0 - 1.2 kg-m, 87 - 112 in-lb)
Starter motor mounting nut:
Bolt a and b :
: 98.1 - 127.0 N·m (10.0 - 13.0 kg-m, 73 - 94 ft-lb)
Bterminalnut:
: 7.3 - 9.8 N·m (0.75 - 1.00 kg-m, 65 - 87 in-lb)
Starter motor mounting nut:
Bolt a :
: 41.2 - 52.0 N·m (4.2 - 5.3 kg-m, 31 - 38 ft - lb)
Bolt b :
: 98.1 - 127.0 N·m (10.0 -13.0 kg-m, 73 -94 ft-lb)
Bterminalnut:
: 9.81 - 11.8 N·m (1.0 - 1.2 kg-m, 87 - 112 in-lb)
Starter motor mounting nut:
: 41.2 - 52.0 N·m (4.2 - 5.3 kg-m, 31 - 38 ft-lb)
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STARTING SYSTEM
Disassembly and Assembly
EKS0031K
1 Sleeve bearing 2 Gear case 3 Stopper clip
4 Pinion stopper 5 Pinion assembly 6 Internal gear
7 Plate 8 Packing 9 Adjusting plate
10 Magnetic switch assembly 11 Planetary gear 12 Ball
13 Packing 14 Yoke 15 Armature
16 Brushholder assembly 17 Rear bearing 18 Rear cover
PKIA0464E
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1 Stopper clip 2 Pinion stopper 3 Pinion
4 Spring 5 Gear case 6 Plate
7 Packing 8 Adjusting plate 9 Magnetic switch assembly
10 Snap ring 11 Retainer ring 12 Over running clutchl
13 Internal gear 14 Planetary gear 15 Ball
16 Packing 17 Cover 18 Yoke
19 Armature 20 Washer 21 Rear bearing
22 Brush holder assembly 23 Brush spring 24 Brush(-)
25 Rear cover
PKIA0465E
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STARTING SYSTEM
Inspection
EKS0031L
MAGNETIC SWITCH CHECK
lBefore starting to check, disconnect battery ground cable.
lDisconnect “M” terminal of starter motor.
1 Pinion stopper clip 2 Pinion stopper 3 Pinion
4 Pinion spring 5 Gear case assembly 6 Shift lever set
7 Dust cover kit 8 Magnetic switch assembly 9 Clutch assembly
10 E-ring 11 Thrust washer 12 Center bracket(P)
13 Packing 14 Planetary gear 15 Internal gear
16 Center bracket (A) 17 Yoke assembly 18 Armature assembly
19 Brush holder assembly 20 Brush(-) 21 Brush spring
22 Thrust washer 23 Rear cover assembly
Through-bolt:
M0T87081
: 4.1 - 7.1 N·m (0.45 - 0.72 kg-m, 39.1 - 62.5 in-lb)
M8T71471
: 5.6 - 10.4 N·m (0.57 - 1.06 kg-m, 49.5 - 92.0 in-lb)
S114-844
: 4.9 - 6.4 N·m (0.50 - 0.65 kg-m,43.4 - 56.4 in-lb)
PKIA0466E
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1. Continuity test (between “S” terminal and switch body).
lNo continuity ... Replace.
2. Continuity test (between “S” terminal and “M” terminal).
lNo continuity ... Replace.
PINION/CLUTCH CHECK
1. Inspect pinion teeth.
lReplace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
lReplace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
lIf it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.
BRUSH CHECK
Brush
Check wear of brush.
lExcessive wear ... Replace.
SEL555E
SEL556E
MEL139L
Wear limit length :Refer to SDS.SC-34,
"Starter".
SEL014Z
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STARTING SYSTEM
Brush Spring Check
Check brush spring pressure with brush spring detached from brush.
lNot within the specified values ... Replace.
Brush Holder
1. Perform insulation test between brush holder (positive side) and
its base (negative side).
lContinuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
lIf brush holder is bent, replace it; if sliding surface is dirty,
clean.
YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.Spring pressure (with
new brush):Refer to SDS.SC-34,
"Starter".
SEL015Z
SEL016Z
SEL019Z
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ARMATURE CHECK
1. Continuity test (between two segments side by side).
lNo continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
lContinuity exists. ... Replace.
3. Check commutator surface.
lRough ... Sand lightly with No. 500 - 600 emery paper.
4. Check diameter of commutator.
lLess than specified value ... Replace.
SEL019Z
SEL020Z
Commutator minimum
diameter:Refer to SDS.SC-34,
"Starter".
SEL021Z
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5. Check depth of insulating mold from commutator surface.
lLess than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
AssemblyEKS0031M
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance (QR engine models)
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “l” between the front edge of
the pinion and the pinion stopper.
lNot in the specified value ... Adjust by adjusting plate.
SEL022Z
Clearance “ ”:Refer to SDS.SC-34,
"Starter".
SEL026Z
SEL633BA