2004 SUBARU FORESTER Service Repair Manual

fuel filter location fuses spark plugs replace clutch 4WD timing belt

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Page 1081 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-6
STARTING/CHARGING SYSTEM
Starter
2. Starter
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(H4SO)-6, REMOVAL, Air Clean

Page 1082 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-7
STARTING/CHARGING SYSTEM
Starter
C: DISASSEMBLY
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.
2) Remove the bolts which

Page 1083 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-8
STARTING/CHARGING SYSTEM
Starter
7) Remove the plate.
8) Remove the shaft assembly and overrunning
clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
Le

Page 1084 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-9
STARTING/CHARGING SYSTEM
Starter
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assem-
bly.
Sleeve bearing
Pinion shaft rotational portion
Shaft spline portion
Inside

Page 1085 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-10
STARTING/CHARGING SYSTEM
Starter
8) Install the yoke to front bracket matching front
bracket to groove of yoke assembly.
9) Install the brush holder to yoke assembly as fol-
lows.
(1) Pres

Page 1086 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-11
STARTING/CHARGING SYSTEM
Starter
13) Connect the connector to terminal M of switch
assembly.
E: INSPECTION
1. ARMATURE
1) Check the commutator for any sign of burns of
rough surfaces or st

Page 1087 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-12
STARTING/CHARGING SYSTEM
Starter
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the

SC(H4SO)-12
STARTING/CHARGING SYSTEM
Starter
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length, and then replace if it ex-
ceeds 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)
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
circuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.
Terminal / Specified resistance:
S — M / Less than 1
Ω
S — Ground / Less than 1 Ω
M — B / More than 1 MΩ
6. SWITCH ASSEMBLY OPERATION
1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.
CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(A) Service limit line
(B) Brush
SC-00102
(A)
(B)
(A) Terminal S
(B) Terminal M
SC-00075
B
M
S
SC-00076
(B) (A)

Page 1088 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-13
STARTING/CHARGING SYSTEM
Starter
7. PINION GAP
1) Measure the pinion gap while the pinion is pulled
out as shown in the figure.
Pinion gap:
0.5 — 2.0 mm (0.020 — 0.079 in)
If the motor

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