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Description
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/
T), clutch pedal switch (M/T), ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's
solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks.
In order to prevent damage caused by excessive rotation of the starter armature when the engine starts,
the clutch pinion gear overruns.

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Troubleshooting

• The battery must be in good condition and fully charged for this troubleshooting.

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Trouble symptom Probable cause Remedy

Engine will not crank Battery charge low Charge or replace battery
 Battery cables loose, corroded or worn Repair or replace cables
out
Transaxle range switch Refer to AT group-automatic transaxle
(Vehicle with automatic transaxle only)
Fuse blown Replace fuse
Starter motor faulty Replace
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded or worn Repair or replace cables
out
Starter motor faulty Replace
Starter keeps running Starter motor faulty Replace
Ignition switch Replace
Starter spins but engine will not crank Short in wiring Repair or replace wiring

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Pinion gear teeth broken or starter Replace
motor
Ring gear teeth broken Replace fly wheel or torque converter
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Specification
Starter
Item Specification
Rated voltage 12 V, 1.7 kW
The number of pinion teeth 11

Performance Ampere Max.105 A

[No-load, 11.5 V] Speed Min. 2,800 rpm

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Components

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1. Front bracket assembly 8. Shield 15. Name plate
2. Clutch set assembly 9. Armature 16. Stop ring
3. Lever assembly 17. Snap ring
4. Lever packing 10. Yoke 18. Overrunning clutch
5. Magnetic switch assembly assembly (ORC) assembly
6. Through bolt 11. Brush holder 19. Internal gear
7. Planet gear assembly assembly
12. Rear bracket 20. Planet shift
assembly assembly
13. Screw
14. Nut

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Description
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch (A/
T), clutch pedal switch (M/T), ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter motor's
solenoid coil.
The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks.
In order to prevent damage caused by excessive rotation of the starter armature when the engine starts,
the clutch pinion gear overruns.

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1. Solenoid
2. Brush assembly
3. Armature
4. Overrun clutch
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Circuit
Diagram

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Removal
1. Turn the ignition switch OFF and disconnect the battery negative (-) terminal.
2. Remove the engine room under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
3. Remove the starter cover (A) after loosening the mounting bolt and nut.

Starter cover mounting nut :

8.8 - 13.7 N·m (0.9 - 1.4 kgf·m, 6.5 - 10.1 Ib·ft)

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4. Disconnect the starter cable (B) from the B terminal on the solenoid, then disconnect the connector (A) from
the S terminal.
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5. Remove the starter mounting bolts (C).

Starter mounting bolt:

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49.0 - 63.7 N·m (5.0 - 6.5 kgf·m, 36.2 - 47.0 Ib·ft)

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6. Remove the starter (A). .c
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Installation
1. Install in the reverse order of removal.
Disassembly
1. Disconnect the M-terminal (A) on the starter solenoid assembly.

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2. After loosening the screws (A), detach the starter solenoid assembly (B).
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3. Loosen the through bolts (A).

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4. Remove the brush holder assembly (A), rear bracket assembly (B) after loosening the mounting screws.
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5. Remove the armature assembly (C) and york assembly (D).
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6. Remove the shield (A).

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7. Remove the lever packing (A) and the planet gear (B).
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8. Remove the clutch set assembly (A) and lever (B).

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Beware of the direction of the lever (A).
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9. Press the stopper (A) using a socket (B).

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10. Remove the stop ring (A) using the stop ring pliers (B).
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11. Remove the stopper (A), overrunning clutch (B), internal gear (C) and planet shaft (D).

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Using a suitable pulling tool (A), pull the overrunning clutch stop ring (B) over the stopper (C).
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Reassembly
1. Reassemble in the reverse order of disassembly.
Inspection

Starter Solenoid Inspection

1. Disconnect the lead wire from the M-terminal of solenoid switch.
2. Connect the battery as shown. If the starter pinion pops out, it is working properly.

• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

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3. Disconnect the battery from the M terminal.

If the pinion does not retract, the hold-in coil is working properly.

• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
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4. Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
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• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.
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Free Running Inspection
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to
starter motor as follows.
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2. Connect a test ammeter (150-ampere scale) and carbon pile rheostats shown is the illustration.
3. Connect a voltmeter (15-volt scale) across starter motor.
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4.
5.
Rotate carbon pile to the off position. .c
Connect the battery cable from battery's negative post to the starter motor body.
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6. Adjust until battery voltage shown on the voltmeter reads 11.5 volts.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly
and freely.
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Items Specification
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Current (Max.) 105

Speed (Min.) 2,800
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Armature Inspection And Test

1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
3. Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or
damage, replace the armature.
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4. Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a lathe
within the following specifications, or recondition with #500 or #600 sandpaper (B).
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5. Measure the commutator (A) runout.
• If the commutator runout is within the service limit, check the commutator for carbon dust or brass chips
between the segments.
• If the commutator run out is not within the service limit, replace the armature.

Commutator runout
Standard (New): 0.05mm (0.0019in.) max
Service limit: 0.08mm (0.0031in.)

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6. Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica (C) between the commutator segments. The undercut should not be too
shallow, too narrow, or v-shaped (D).

Commutator mica depth

Standard (New) : 0.8 mm (0.314 in.)
Limit : 0.2mm (0.0079 in.)
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7. Check for continuity between the segments of the commutator. If an open circuit exists between any
segments, replace the armature.
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8. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B),
and between the commutator and armature shaft (C). If continuity exists, replace the armature.

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Inspect Starter Brush
Any worn out or oil-soaked brushes should be replaced.
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Starter Brush Holder Test
1. Check that there is no continuity between the (+) brush holder (A) and (-) plate (B). If there is continuity,
replace the brush holder assembly.

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2. Pry back each brush spring (A) with a screwdriver, then position the brush (B) about halfway out of its
holder, and release the spring to hold it there.
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3. Install the armature in the housing, and install the brush holder. Next, pry back each brush spring again, and
push the brush down until it seats against the commutator, then release the spring against the end of the
brush.

To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the
commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes will be
sanded to the same contour as the commutator.

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Inspect Overrunning Clutch

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1. Slide the overrunning clutch along the shaft.

Replace if it does not slide smoothly.
2. Rotate the overrunning clutch both ways.
Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction or locks in
both directions, replace it.
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3. If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (The gear is not
available separately.)
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Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.
Cleaning
1. Do not immerse parts in cleaning solvent.
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Immersing the yoke assembly and/or armature will damage the insulation wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent.
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The overrun clutch is pre-lubricated at the factory and solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
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Inspection
1. Turn ignition switch OFF and disconnect the negative (-) battery terminal.
2. Remove the fuse box cover.
3. Remove the starter relay (A).

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4. Check for continuity between the terminals (30 and 87) using an ohmmeter.
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Terminal Resistance Measure

If there is continuity between
30 - 87 1M or higher
the terminals, replace the relay.
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5. Apply 12V to the terminal 85 and ground to the terminal 86 and then check for continuity between
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the terminals (30 and 87).
Terminal Resistance Measure
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If there is no continuity
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30 - 87 1 or less between the terminals, replace

the relay.
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6. Install the starter relay.
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7. Install the fuse box cover.
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