Starting System: Starter: Inspection

1. Check the commutator for open circuit.

   Using an ohmmeter, measure the resistance between the segments of the commutator.

   Standard: Below 1 Ω 

   If the result is not as specified, replace the armature.

   Fig 1: Measuring Resistance Between Segments Of Commutator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the commutator for ground.

   Using an ohmmeter, measure the resistance between the commutator and armature coil core.

   Standard: 10 MΩ or higher 

   If the result is not as specified, replace the armature.

1. Check the commutator for the dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or on a lathe.
   Fig 2: Measuring Resistance Between Commutator And Armature Coil Core

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check for the commutator circle runout.
   1. Place the commutator on V-blocks.
   2. Using a dial gauge, measure the circle runout.

      Maximum circle runout: 0.05 mm (0.0020 in.) 

      If the circle runout is greater than the maximum, correct it on a lathe.

      Fig 3: Measuring Circle Runout

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers, measure the commutator diameter.

   Standard diameter: 30.0 mm (1.181 in.) 

   Minimum diameter: 29.0 mm (1.142 in.) 

   If the diameter is less than the minimum, replace the armature.

   Fig 4: Measuring Commutator Diameter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.

   Standard undercut depth: 0.6 mm (0.024 in.) 

   Minimum undercut depth: 0.2 mm (0.008 in.) 

   If the undercut depth is less than the minimum, correct it with a hacksaw blade.

   Fig 5: Checking Undercut Depth

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the field coil for open circuit.

   Using an ohmmeter, measure the resistance between the lead wire and field coil brush lead.

   Standard: Below 1 Ω 

   If the result is not as specified, replace the field frame.

   Fig 6: Measuring Resistance Between Lead Wire And Field Coil Brush Lead

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the field coil for ground.

   Using an ohmmeter, measure the resistance between the field coil brush lead and field frame.

   Standard: 10 MΩ or higher 

   If the result is not as specified, repair or replace the field frame.

   Fig 7: Measuring Resistance Between Field Coil Brush Lead And Field Frame

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using vernier calipers, measure the brush length.

Standard length: 15.5 mm (0.610 in.) 

Minimum length: 10.0 mm (0.393 in.) 

If the length is less than the minimum, replace the brush holder and field frame.

Fig 8: Measuring Brush Length

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Check the brush spring load.

Take the pull scale reading the instant the brush spring separates from the brush.

Standard spring installed load: 

17.6 to 23.5 N (1.80 to 2.40 kgf, 4.0 to 5.3 lbf) Minimum spring installed load: 11.8 N (1.2 kgf, 2.6 lbf) 

If the installed load is less than minimum replace the springs.

Fig 9: Checking Brush Spring Load

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Check the brush holder insulation.

Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

Standard: 10 MΩ or higher 

If the result is not as specified, repair or replace the brush holder.

Fig 10: Checking Brush Holder Insulation

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1. Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage.

   If damaged, replace the gear or clutch assembly.

   If damaged, also check the ring gear of the flywheel/drive plate for wear or damage.

2. Check the clutch pinion gear.

   Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.

   If necessary, replace the clutch assembly.

   Fig 11: Checking Clutch Pinion Gear

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1. Check the pull-in coil for open circuit.

   Using an ohmmeter, measure the resistance between terminals 50 and C.

   Standard: Below 1 Ω 

   If the result is not as specified, check and replace the magnetic switch.

   Fig 12: Measuring Resistance Between Terminals 50 And C

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the hold-in coil for open circuit.

   Using an ohmmeter, measure the resistance between terminal 50 and the switch body.

   Standard: Below 2 Ω 

   If the result is not as specified, replace the magnetic switch.

   Fig 13: Measuring Resistance Between Terminal 50 And Switch Body

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn the bearing by hand while applying inward force.

If resistance is felt or the bearing sticks, replace the bearing (see REPLACEMENT ).