SECTION 6E - ENGINE ELECTRICAL -

STARTING SYSTEM

Main Data & Speci fications

General Description

Starting Circuit Diagram

Wire Coding

Description

Wire Size

Wire Size Specifications

Wire Color

Wire Color-Coding

Symbols & Abbreviations

Description

Symbols

Symbol & Meaning

Abbreviations

Abbreviation & Meaning

Torque Specifications

Starter Motor

Removal & Installation

Disassembly

Inspection & Repair

Armature

Yoke

Brush & Brush Holder

Overrunning Clutch

Bearing

Magnetic Switch

Reassembly

Troubleshooting

Hard Starting

1. Pinion Does Not Engage The Ring Gear When The Starter Switch Is Turned On

2. Pinion Engages The Ring Gear But The Engine Does Not Turn Over

3. Incorrect Pinion And Ring Gear Engagement

4. Starter Continues To Run After The Starter Switch Is Turned Off

5. Excessive Commutator Sparking

Main Data & Specifications

Item Description

Starter Motor

Type

Rated voltage V Solenoid controlled

Rated output kW 2.3

Load characteristics

Terminal voltage V

Load current A 8.76

300

General Description

The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor, starter switch with safety

lock, etc. The starter motor circuit utilizes negative ground polarity.

Starting Circuit Diagram

Wire Coding

Description

Codes used in the circuit diagram represent wire size and

color Q.

Example: 0.5 R

Wire color (Red)

Wire size (0.5 mm2)

Wire Size

Wire size is specified with the metric gauge system.

The metric gauge system gives the wire size in cross-

sectional area measured in square millimeters.

Wire Size Specifications

Wire size

mm2AWG

Number of wires/

Wire diameter

mm (in.)

Resistance at normal room

temperature of 20°C (68°F)

Ω/m (Ω/ft.)

Maximum allowable

current

0.5

0.85

1.25

7/0.32 (0.013)

11/0.32 (0.013)

16/0.32 (0.013)

26/0.32 (0.013)

41/0.32 (0.013)

65/0.32 (0.013)

50/0.45 (0.018)

84/0.45 (0.018)

41/0.80 (0.031)

70/0.80 (0.031)

0.03250 (0.00991)

0.02050 (0.00625)

0.01410 (0.00430)

0.00867 (0.00264)

0.00550 (0.00168)

0.00347 (0.00106)

0.00228 (0.00070)

0.00136 (0.00042)

0.00087 (0.00027)

0.00051 (0.00016)

11.3

14.8

18.8

25.4

34.2

45.9

59.8

82.8

110.9

147.0

Wire Color

All wires have color-coded insulation.

Wires belonging to a system’s main harness will have a

single color Q.

Wires belonging to a system’s sub-circuits will have a

colored stripe R.

Striped wires use the following code to show wire size and

colors.

Example: 0.5 G R

Wire size (0.5 mm2)

Green (Base color)

Red (Stripe color)

Abbreviations are used to indicate wire color within a

circuit diagram.

Refer to the following table.

Wire Color-Coding

Color-coding Meaning Circuits

B Black Starter circuit and grounding circuit

W White Charging circuit

R Red Lighting circuit

G Green Signal circuit

Y Yellow Instrument circuit

L Blue Wiper circuit

O Orange

Br Brown

Lg Light green

Gy Grey

PPink

Sb Sky blue

V Violet

Other circuits

Symbol s & Abbreviations

Description

The symbols and abbreviations used in the circuit diagram

make the diagram easier to read and understand.

Symbols

The illustration at the left shows a ty pical symbol Q used

in circuit diagrams.

Refer to the following table.

Symbol & Meaning

Symbol Meaning Symbol Meaning

Fuse Single filament bulb

Main fuse Double filament bulb

Fusible link wire Motor

Switch Variable resistor

Switch Coil (Inductor)

Contact wiring

Battery

Relay

Note:

Relay contact shown in the

wiring diagram indicates

condition before a ctuation.

Diode Connector

Electronic part Light emitting diode

Resistor Reed switch

Speaker Condenser

Abbreviations

The illustration at the left shows a ty pical abbreviation 

used in circuit diagrams.

These same abbreviations may also appear in the next.

Refer to the following table.

Abbreviation & Meaning

Abbreviation Meaning Abbreviation Meaning

M/T

A/T

FLW

TEMP

ECM

Right-hand side

Left-hand side

Switch

Manual transmission

Automatic transmission

Front

Rear

Fusible link wire

Temperature

Electronic control module

STD

OPT

WO/

ACC

A/C

ATF

VSV

Standard equipment

Optional equipment

With

Without

Overdrive

Accessories

Air conditioner

Automatic transmission fluid

Vacuum switching valve

Torque Specifi cati ons

Starter Motor kgm(ft. lbs/Nm)

Starter Motor

Removal & Installation

Read this Section carefully before performing any removal and installation procedure. This Section gives you important

points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

IMPO RTANT OPERATIONS - REMOVAL

Starter Motor

1) Disconnect the battery cable and the ground cable at

the battery terminals.

2) Disconnect the magnetic switch cable at the terminal

bolts.

3) Disconnect the battery cable at the starter motor and

the ground cable at the cylinder body.

4) Remove the starter motor from the engine.

IMPORTANT OPERATIONS – INSTALLATION

Follow the removal procedure in the reverse order to

perform the installation procedure. Pay careful attention to

the important points during the installation procedure.

Starter Motor

1) Install the starter motor to the rear plate.

2) Tighten the starter motor bolts to the specified torque.

Starter Motor Bolt Torque kg⋅m(lb⋅ft/N⋅m)

7 ± 1 (50.6 ± 7.2/68.7 ± 9.8)

3) Reconnect the battery cable at the starter motor and

the ground cable at the cylinder body.

4) Reconnect the battery cable and the ground cable at

the battery terminals.

Disassembly

DISASSEMBLY STEPS

1. Lead wire

14. Armature

2. Bolt 15. Screw

3. Magnetic switch assembly

16. Bearing retainer

4. Torsion spring

17. Pinion assembly

5. Plunger 18. Pinion stopper clip

6. Adjusting shims 19. Pinion stopper

7. Magnetic switch 20. Return spring

8. Screw 21. Pinion shaft

9. Through bolt 22. Clutch

10. Rear cover

23. Dust cover

11. Motor assembly

24. Shift lever

12. Brush holder

25. Gear case

13. Yoke

IMPORTANT OPERATIONS

1. Lead Wire

Disconnect the lead wire at the magnetic switch.

3. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove the

switch from the shift lever.

Remove the torsion spring from the magnetic switch.

1. Screw

2. Through Bolt

3. Rear Cover

Remove the through bolts, then remove the rear cover.

4. Motor Assembly

Remove the four brushes from the brush holders.

Remove the yoke along with the armature and the brush

holder from the gear case.

Remove the brushes and commutator carefully so as not

to allow them in contact with the adjacent parts.

5. Brush Holder

6. Yoke

7. Armature

Remove the brush holder and pull out the armature

assembly free from the yoke.

15. Bearing Retainer

16. Pinion Assembly

23. Dust Cover

24. Shift Lever

25. Gear Case

1. Remove the bearing retainer.

2. Remove the pinion from the gear case.

3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.

Inspection & Repair

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during

inspection.

Armature

1. Measure the commutator run-out.

Replace the commutator if the measured run-out

exceeds the specified limit.

Commutator Run-Out mm (in)

Standard Limit

0.02 (0.001) 0.05 (0.002)

2. Check the commutator mica segments for excessive

wear.

3. Measure the mica segment depth.

Mica Segment Depth mm (in)

Standard Limit

0.7 – 0.9 (0.028 – 0.035) 0.2 (0.01)

If the mica segment depth is less than the standard but

more than the limit, the commutator may be reground.

If the mica segment depth is less than the limit, the

commutator must be replaced.

4. Measure the commutator outside diameter.

Commutator Outside Diameter mm (in)

Standard Limit

35 (1.4) 34 (1.3)

If the measured outside diameter is less than the specified

limit, the commutator must be replaced.

5. Test the armature for short circuiting.

a. Place the armature in a growler tester.

b. Hold a hacksaw blade against the armature core.

If the armature has a short circuit, the hacksaw blade

will vibrate.

Replace the armature if there is a short circuit.

6. Use a circuit tester to check the armature for

grounding.

1) Hold one probe of the circuit tester against the

commutator segment.

2) Hold the other circuit tester probe against the

armature core.

If the circuit tester indicates continuity, the armature is

grounded.

The armature must be replaced.

7. Use the circuit tester to check the armature for

continuity.

1) Hold the circuit tester probes against two armature

core segments.

2) Repear Step 1 at different segments of the

armature core.

There should be continuity between all segments of

the armature core.

If there is not, the armature must be replaced.

Yoke

1. Use a circuit tester to check the field winding ground.

1) Hold one circuit tester probe against the field

winding end or brush.

2) Hold the other circuit tester probe against the bare

surface of the yoke body.

There should be no continuity.

If there is continuity, the field coil is grounded.

The yoke must be replaced.

2. Use the circuit tester to check the field winding

continuity.

1) Hold one circuit tester probe against the “C”

terminal lead wire.

2) Hold the other circuit tester probe against the field

winding brush.

There should be continuity.

If there is no continuity, the yoke must be replaced.

Brush & Brush Holder

1. Use a vernier caliper to measure the brush length (four

brushes).

Replace the brushes as a set if one or more of the

brush lengths is less than the specified limit.

Brush Length mm (in)

Standard Limit

14.5 (0.57) 9.5 (0.37)

2. Use a circuit tester to check the brush holder

insulation.

Touch one probe to the holder plate and the other

probe to the positive brush holder.

There should be no continuity.

3. Inspect the brushes for excessive wear.

If the negative brushes have excessive wear, the

entire brush holder assembly must be replaced.

If the positive brushes have excessive wear, only the

brushes must be replaced.

1) Use a pair of side cutters to cut the lead wire from

the brush.

2) File away any foreign material clinging to the edge

of the lead wire.

3) Remove the brushes from the brush holder.

4) Install the new brushes.

5) Straighten the bent portion of the clip.

6) File away any foreign material clinging to the clip

surface.

7) Place the lead wire in the clip.

8) Bend the clip shut.

9) Solder the brush lead.

10) Repeat the procedure for each of the brushes.

Overrunning Clutch

1. Inspect the overrunning clutch gear teeth for

excessive wear and damage.

Replace the overrunning clutch if necessary.

2. Rotate the pinion clockwise.

It should turn smoothly.

3. Try to rotate the pinion in the opposite direction.

The pinion should lock.

Bearing

Inspect the bearings for excessive wear and damage.

Replace the bearings if necessary.

Magnetic Switch

The following tests must be performed with the starter

motor fully assembled.

The yoke lead wire must be disconnected from the “C”

terminal.

To prevent coil burning, complete each test as quickly as

possible (within three to five seconds).

Temporarily connect the solenoid switch between the

clutch and the housing and run the following test.

Complete each test within three to five seconds.

1. Pull-in Test

Connect the battery negative terminal with the solenoid

switch body and the C terminal. When current is applied to

the 50 terminal from the battery positive terminal, the

pinion should flutter.

2. Hold-in Maintenance Test

Disconnect the lead at the C terminal. The pinion should

continue to flutter.

3. Return Test

Connect the battery negative leads to the starter body and

the 50 terminal.

Connect the battery positive lead at the C terminal.

The pinion should return to its home position.

Reassembly

REASSEMBLY STEPS

1. Magnetic switch assembly 14. Pinion stopper

2. Magnetic switch 15. Pinion stopper clip

3. Adjusting shims 16. Bearing retainer

4. Plunger 17. Screw

5. Torsion spring 18. Motor assembly

6. Shift lever 19. Armature

7. Gear case 20. Yoke

8. Dust cover

21. Brush holder

9. Bolt 22. Rear cover

10. Pinion assembly 23. Screw

11. Clutch

24. Through bolt

12. Pinion shaft

25. Lead wire

13. Rerurn spring

IMPORTANT OPERATIONS

1. Magnetic Switch Assembly

1. Attach the torsion spring to the hole in the magnetic

switch as illustrated.

2. Insert the shift lever into the plunger hole of the

magnetic switch.

7. Gear Case

8. Dust Cover

1. Install the magnetic switch assembly in the gear case.

2. Install the dust cover.

Dust Cover Bolt Torque kg⋅m(lb⋅ft/N⋅m)

0.75 ± 0.5 (5.4 ± 3.6/7.4 ± 5)

10. Pinion Assembly

Apply a coat of grease to the reduction gear and install the

pinion assembly to the armature shaft.

21. Brush Holders

1. Install the brushes into the brush holder with raising

the spring end of the brush spring.

Take care not to damage the commutator face.

2. Install the brush holder with aligning the peripheries of

the yoke and the brush holder.

24. Through Bolt

Install the through bolts in the rear cover and tighten them

to the specified torque.

Through Bolt Torque kg⋅m(lb⋅ft/N⋅m)

0.6 ± 0.1 (4.3 ± 0.7/5.9 ± 1.0)

25. Lead Wire

Connect the lead wire in the magnetic switch and tighten

the terminal nut to the specified torque.

Lead Wire Terminal Nut Torque kg⋅m(lb⋅ft)

0.8 ± 0.1 (5.8 ± 0.7/7.8 ± 1.0)

Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust

play.

The pinion shaft thrust play is equal to the pinion shaft end

and pinion stopper clearance.

Pinion Shaft Thrust Play mm (in)

0.3 - 1.5 (0.01 – 0.06)

In a case where the pinion gap outside the

specified value;

Make an adjustment using a shim(s).

Adjusting shims are available in 0.5 mm and 0.8 mm (0.02 and

0.03 in.) sizes.

Troubleshooting

Refer to this Section to quickly diagnose and repair electrical problems.

Each troubleshooting chart has three headings arranged from left to right.

(1) Checkpoint (2) Trouble Cause (3) Countermeasure

Hard Starting

1. Pinion Does Not Engage The Ring Gear When The Starter Switch Is Turned On

2. Pinion Engages The Ring Gear But The Engine Does Not Turn Over

3. Incorrect Pinion And Ring Gear Engagement

4. Starter Continues To Run After The Starter Switch Is Turned Off

5. Excessive Commutator Sparking

Hard Starting

1. Pinion Does Not Engage The Ring Gear When

The Starter Sw itch Is Turned On

Checkpoint Trouble Cause Countermeasure

Battery Discharged Recharge

Starter circuit Open or intermittent Clean and reconnect

Magnetic solenoid switch Contact points defective Replace

Magnetic solenoid coil Open or scorched Replace

Plunger shaft Bent or scorched Bent or scorched

OKOK

2. Pinion Engages The Ring Gear But The Engine Does Not Turn Over

Checkpoint Trouble Cause Countermeasure

Battery Weak Recharge

Brush and commutator face

contact Intermittent Repair or replace

Face dirty Clean

Pinion clutch Slippage Replace

Armature field coil Open or short circuit Repair of replace

OKOK

3. Incorrect Pinion & Ring Gear Engagement

Checkpoint Trouble Cause Count ermeasure

4. Starter Continues To Run After The Starter Switch Is Turned Off

Checkpoint Trouble Cause Count ermeasure

Battery Discharged Recharge

Pinion and ring gear teeth Worn or broken Replace

Pinion gear return movement Incorrect Adjust

OKOK

Magnetic solenoid switch

contact points Seized Repair or replace

Starter switch Defective Replace

OKOK

5. Excessive Commutator Sparking

Checkpoint Trouble Cause Count ermeasure

Brush and commutator face

contact Intermittent Repair or replace

Slag accumulation on the face Clean or replace

Commutator Excessive wear or pitting Repair or replace

Loose solder Clean and repair

Armature shaft Run-out due to worn bearing Repair

Brush holder Loose in mount Repair