19–2

STARTING & CHARGING – STARTER ASSY

190OI–01

OVERHAUL

1. REMOVE REPAIR SERVICE STARTER KIT

(a) Remove the nut, and disconnect the lead wire from the re-
pair service starter kit.

A81555

(b) Remove the 3 nuts holding the repair service starter kit to
the starter housing.
(c) Remove the repair service starter kit.
(d) Remove the return spring and plunger.

A82635

2. REMOVE STARTER YOKE ASSY

(a) Using a torx driver T25, remove the 2 through bolts and
pull out the starter yoke together with the starter commu-
tator end frame.

A82636

(b) Remove the starter yoke from the starter commutator end
frame.

A82637

3. REMOVE STARTER ARMATURE ASSY

(a) Remove the starter armature assy from the starter yoke assy.

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

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STARTING & CHARGING – STARTER ASSY

4. REMOVE STARTER ARMATURE PLATE

(a) Remove the armature plate from the starter yoke.

A79722

5. REMOVE STARTER BRUSH HOLDER ASSY

(a) Remove the 2 screws and brush holder assy from the
commutator end frame.

A82638

6. REMOVE PLANET GEAR

(a) Remove the 3 planet gears from the repair service starter
kit.

A82639

7. INSPECT REPAIR SERVICE STARTER KIT

(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly
to its original position.
If necessary, replace the repair service starter kit.

A82640

(b) Check the pull–in coil for open circuit.

Terminal C (1) Using an ohmmeter, check that there is continuity
between terminals 50 and C.
If there is no continuity, replace the repair service starter kit.

Continuity
Terminal 50

A82641

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

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STARTING & CHARGING – STARTER ASSY

(c) Check if the hold–in coil has an open circuit.

(1) Using an ohmmeter, check that there is continuity
between terminal 50 and the switch body.
If there is no continuity, replace the repair service kit.

Continuity

Terminal 50

A82642

8. INSPECT STARTER ARMATURE ASSY

Continuity (a) Check the commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the segments of the commutator.
If there is no continuity between any segments, replace the ar-
mature.

A82643

(b) Check the commutator for ground.

(1) Using an ohmmeter, check that there is no continu-
ity between the commutator and the armature coil
core.
If there is continuity, replace the armature.

No Continuity A82644

(c) Check the commutator for dirty or burned surface.

If the surface is dirty or burnt, smooth the surface with 400–grit
sandpaper.
(d) Check for the commutator circuit runout.
(1) Place the commutator on V–blocks.
(2) Using a dial indicator, measure the circle runout.
Standard runout: 0.02 mm (0.0008 in.)
Maximum runout: 0.05 mm (0.0020 in.)
A82645 If the runout is greater than maximum, replace the armature.

(e) Using vernier calipers, measure the commutator diame-

29mm
ter.
Standard length: 29 mm (1.142 in.)
Minimum length: 28 mm (1.102 in.)
If the diameter is less than minimum, replace the armature.

A82646

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)

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STARTING & CHARGING – STARTER ASSY

9. INSPECT STARTER BRUSH HOLDER ASSY

(a) Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Length Minimum length: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the starter brush
holder assy.

A82647

No Continuity (b) Check the brush holder.

(1) Using an ohmmeter, check that there is no continu-
ity between the positive (+) and negative (–) brush
holders.
If there is continuity, repair or replace the starter commutator
end frame assy.

A82648

10. INSPECT REPAIR SERVICE STARTER KIT

Lock
(a) Check the starter clutch.
(1) Rotate the clutch pinion gear counterclockwise and
check that it turns freely. Try to rotate the clutch pin-
ion gear clockwise and check that it locks.
If necessary, replace the repair service starter kit.

Free

A82649

11. INSTALL PLANET GEAR

(a) Apply grease to the planet gears and pin parts of the plan-
Apply Grease etary shaft.
(b) Install the 3 planet gears.

A82650

12. INSTALL STARTER BRUSH HOLDER ASSY

(a) Install the brush holder to the starter armature assy.

A82651

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STARTING & CHARGING – STARTER ASSY

13. INSTALL STARTER COMMUTATOR END FRAME

ASSY
(a) Install the commutator end frame with the 2 screws.

A82652

14. INSTALL STARTER ARMATURE ASSY

(a) Align the rubber with the convex cutout of starter yoke.
(b) Install starter armature with the brush holder to the starter
yoke.

A82653

Key 15. INSTALL STARTER ARMATURE PLATE

(a) Insert the starter armature plate to the starter yoke.
Keyway
(b) Align the keyway of the starter plate with the key inside the
starter yoke, and install the starter plate.

A82654

16. INSTALL STARTER YOKE ASSY

(a) Align the key of the starter yoke with the keyway located
on the starter drive housing.

Key
Keyway

A81586

(b) Using a torx driver T25, install the starter yoke with the 2
through bolts.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)
17. INSTALL REPAIR SERVICE STARTER KIT
(a) Apply grease to the plunger and hook.
(b) Set the plunger and hook of the repair service starter kit
to the drive lever.
(c) Install the plunger and return spring.
A82636

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STARTING & CHARGING – STARTER ASSY

(d) Install the repair service starter kit with the 3 nuts.
Torque: 2.3 N
m (24 kgf
cm, 21 in.
lbf)

A82635

(e) Connect the lead wire to the repair service starter kit and
then fasten it with the nut.
Torque: 6.0 N
m (61 kgf
cm, 53 in.
lbf)

A81555

1AZ–FSE ENGINE REPAIR MANUAL (RM1019E)