EE

CONTENTS
ADJUSTMENT VALUE ....................................... EE-2
TROUBLE DIAGNOSIS ...................................... EE-3
STARTER MOTOR (DRY TYPE) ........................ EE-4
Specifications ................................................. EE-4
Components ................................................... EE-4
Component Parts Location ............................. EE-5
Overhaul ......................................................... EE-6
Assembly Inspection ...................................... EE-7

STARTER MOTOR (WET TYPE) ....................... EE-8

Specifications ................................................. EE-8
Components ................................................... EE-8
Exploded View ............................................... EE-9
Inspection ..................................................... EE-10
ALTERNATOR .................................................. EE-11
Exploded View ............................................. EE-11
Disassembly ................................................. EE-12
Inspection ..................................................... EE-14

EE

ADJUSTMENT VALUE

Component
Starter motor

Items

Brush dimensions

Description
Dry type

5.5 - 12.3 mm (0.217 - 0.484 in)

(Wear margin 6.8 mm (0.27 in))

Wet type

12.0 - 16.0 mm (0.472 - 0.630 in)

(Wear margin 4 mm (0.16in))

Dry type

15.0 - 20.4 N (1.53 - 2.08 kg, 3.4 - 4.59 lb)

Brush spring pressure

Stator

Resistance between respective lead wires: 0.05 - 0.5

Resistance between stator core and lead wire:

Rotor coil

Standard resistance between slip rings: 2.41 - 2.82

Standard resistance between slip ring and rotor core:

Snap ring

Snap ring outer diameter: Standard: 22.7 mm (0.894 in)

Repair limit: 22.1 mm (0.870 in)

Brush

Projected length from holder:

Standard: 10.0 mm (0.394 in) or more

Wet type
Alternator

EE-2

17.7 - 21.6 N (1.81 - 2.20 kg, 3.98 - 4.86 lb)

TROUBLE DIAGNOSIS

Condition
No or slow cranking

Engine is cranked but

not started.

Possible causes

Action

Battery is discharged

Check and repair the charging system, check and adjust the fan belt for
tension, or replace the battery

Incident in starter system wiring

Check and repair or replace the starter switch.

Starter motor malfunction

Repair or replace.
(Starter circuit diagnosis procedure)
If the light turns off or dims when the starter switch is turned to ON with the
headlights on:
a: Check the battery.
b: Check the electric connections and wiring.
c: Check the starter motor.
If the light remains bright when the starter switch is turned to ON with the
headlights on:
a: Check the wiring between battery and starter motor.
b: Check the starter switch.
c: Check the starter motor.

Incident in ignition system

(Another possible cause is an
incident in the fuel system. Refer to
the section about the fuel system)

(Ignition system diagnosis procedure)

Inspect the spark plug following the steps below
Disconnect the IGN/coil from the No. 1 plug and keep the cord 10 mm (0.394
in) away from the engine metal portions. Then crank the engine. If there is
difficulty in identifying a spark, use the following approach: connect the IGN/
coil to a new spark plug that is separately prepared, contact the thread of the
plug to the engine metal and check for a spark by activating the starter.
If a good spark is available:
a: Check the spark plug.
b: Check the ignition timing.
c: Check the fuel system.
d: Check the cylinder compression.
If no spark is available:
a: Check the primary coil current.
b: If the current is too large, a short circuit may be present, replace.
c: Check coil malfunction, replace.
d: If the IGN/coil has an open circuit, Replace.

EE-3

STARTER MOTOR (DRY TYPE)

STARTER MOTOR (DRY
TYPE)

Specifications
Item

Specifications

Part type

For dry type clutch

Type

Built in reduction gear

Output

(kW)

Components

EE-4

1.2

STARTER MOTOR (DRY TYPE)

Component Parts Location
Major components of starter motor
Symbol

Description

(1)

Front bracket

(2)

Overrunning clutch

(3)

Lever

(4)

Internal gear

(5)

Packing

(6)

Shaft gear

(7)

Gear assembly

(8)

Packing

(9)

Armature

(10)

Yoke assembly

(11)

Connector brush holder assembly

(12)

Rear bracket

(13)

Switch assembly

(14)

Hexagon head bolt

(15)

Flange screw

EE-5

STARTER MOTOR (DRY TYPE)

Overhaul
RELATED TO MAGNET SWITCH

1.

2.
EEM0124

Plunger sliding face (rust, contamination, deformation)

Broken or worn return spring
Rough surface of main contact (burnout)
Operation check of magnet switch
(Proper performance of magnet coil)
Plunger's drawing operation (Pull-in coil operation)
Wire the plunger as shown in the figure on the left. The plunger
should be drawn strongly by the pull-in coil and holding coil.
Plunger's holding operation (Holding coil operation)
In the above circuit, disconnect the wiring from the terminal M.
If the holding coil is normal, the plunger should be held in
place.

EEM0125

PINION MECHANISM

Damage or wear of pinion gear tooth tops

Visually check for damage or wear. Replace the gear if the
damage/wear is excessive.
Pinion gear sliding face (rust, contamination, damage on spline)
Check the pinion gear sliding motion. Replace the gear(s), if the
gear(s) drag excessively.
Overrunning clutch operation (slippage, seizure)
Turn the pinion gear by hand. If it turns freely in both directions
or will not turn in either direction, the overrunning clutch has
lost its proper functionality. Replace it.

ARMATURE COIL

Check the continuity between the commutators.

Judgement:
If there is continuity, the armature coil is normal.
If there is no continuity, the coil has an open circuit.
Replace it.

EEM0128

EE-6

STARTER MOTOR (DRY TYPE)

Overhaul (Contd)

Check for continuity between the armature coil and a ground.

Judgement:
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.

EEM0129

BRUSH COMMUTATOR RELATED

Brush wear: mm (in)

5.5 - 12.3 (0.217 - 0.484)

(Wear margin: 6.8 (0.27) max.)

Brush spring pressure N (kg, lb)

15.0 - 20.4 (1.53 - 2.08, 3.4 - 4.59)

If the commutator has a rough surface, grind it using sandpaper

of #500 or #600.
If the insulator (high mica) of the commutator is 0.5 - 0.8 mm
(0.020 - 0.031 in) or less in thickness, replace the commutator.

Assembly Inspection

Inspection for abrasion between the armature core and the

magnet.
Starter motor inspection (performance with no load)

EEM0131

PROCEDURE

Connect an ammeter to the battery positive terminal and the B

terminal.
Connect a test wire to the B terminal and S terminal.
Connect a voltmeter to the B terminal and the starter motor
body.
Connect a test wire to the battery negative terminal and the
starter motor body.

Judgement:
The pinion gear should pop out and the starter motor
should rotate.

EE-7

STARTER MOTOR (WET TYPE)

STARTER MOTOR (WET
TYPE)

Specifications
Item

Specifications

Part type

For wet type clutch

Type

Built in reduction gear

Output

(kW)

Components

EE-8

1.4

STARTER MOTOR (WET TYPE)

Exploded View
Major components of starter motor

(1)
(2)
(3)
(4)
(5)
(6)

Armature coil
Ball bearing
Ball bearing
Field coil
Pole core set screw
Brush (positive)

(7)
(8)
(9)
(10)
(11)
(12)

Rear cover
Brush holder
Brush (negative)
Brush spring
Gear case
Shift lever set

EE-9

(13)
(14)
(15)
(16)

Magnetic switch
Dust cover set
Bolt (M6X32)
Through bolt

STARTER MOTOR (WET TYPE)

Inspection
FIELD COIL
Check for continuity between the field coil and a ground.
Judgement:
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.

EEM0127

CAUTION:
Note that, however, a compound-wound motor structurally
grounds the field coil. This means that the tester will show
continuity between the field coil and a ground.
ARMATURE COIL

Check the continuity between the commutators.

Judgement:
If there is continuity, the armature coil is normal.
If there is no continuity, the coil has an open circuit.
Replace it.

EEM0128

Check for continuity between the armature coil and a ground.

Judgement:
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.

EEM0129

BRUSH COMMUTATOR RELATED

Brush wear: mm (in)

12.0 - 16.0 (0.472 - 0.630)

(Wear margin: 4 (0.16) max.)

Brush spring pressure N (kg, lb)

17.7 - 21.6 (1.81 - 2.20, 3.98 - 4.86)

If the commutator has a rough surface, grind it using sandpaper

of #500 or #600.
If the insulator (high mica) of the commutator is 0.5 - 0.8 mm
(0.02 - 0.03 in) or less in thickness, replace the commutator.

EE-10

ALTERNATOR
ALTERNATOR

Exploded View

EE-11

ALTERNATOR
Disassembly
1.

Remove 4 through bolts of front cover and rear cover.

2. Disassembly of front cover and rear cover

Insert the tip of a screwdriver into the clearance between the stator
and the front cover, and then disassemble the front cover and the
rear cover.
NOTE:
Do not damage the stator coil and do not peel the lamination of stator core with a screwdriver.

3. Disassembly of front cover assembly

(a) Secure the rotor using a vice to prevent the rotor pole or the fan
from deformation.
(b) Remove the pulley tightening nuts, and then remove the pulley,
spacer, and front cover.
NOTE:
When securing the rotor using a vice, hold the bottom of the pole to
prevent the rotor pole from deformation. Also be careful not to drop
each part when loosening.

4. Removal of front bearing

When replacing the front bearing, remove the retainer tightening
screw, and then push the front bearing out using a jig (that is closest
to the outer diameter of spacer) with handpress.

EE-12

ALTERNATOR
Disassembly (Contd)
5. Removal of rear bearing
Remove the rear bearing using the commercial bearing puller when
replacing.
NOTE:

Be careful not to damage the snap ring molding by the tabs of

bearing puller because the clearance between the rear bearing
and the slip ring is too narrow.

Do not reuse the rear bearing.

6. Removal of regulator assembly

(a) Remove the regulator assembly mounting screws (two M5
screws).

(b) Disengage the regulator assembly soldering areas (2 locations),

and then remove the regulator assembly while lifting the stator
up.
NOTE:
Remove the plate R in advance and lightly press the connector for
easier disassembly.
In addition, it is easy to disassemble the soldering areas when
opening the opening of the caulking area because it was caulked.

7. Removal of stator
Disassemble the soldering area of stator coil lead wire, and then
remove the stator from the diode assembly.
NOTE:
The stator coil lead wire is soldered on the rectifier terminal in high
temperature solder (melting point 230C (446F) specifications).
Quickly remove the soldering iron of 100 - 250W so as not to damage the diode because the diode assembly is overheated.
In addition, it is easy to disassemble the diode lead when opening
the opening of caulking area because it was caulked.

EE-13

ALTERNATOR
Disassembly (Contd)
8. Removal of diode assembly
(a) Remove the diode assembly tightening screw.
(b) Removal of terminal B
Example (1): Press in type side-projection terminal B
Remove the circular cover and nut, press in the top of terminal B bolt from rear side, and then remove the terminal
B that is pressed in.
Example (2): Rear-projection terminal B
Remove the terminal B nut and terminal B molding.

Inspection
STATOR COIL
1. Continuity inspection of coil (with circuit tester)
Check for continuity between 2 coil lead wires.
Check between N lead line (bundled line) and each phase. (Three
phases)
Standard:
Resistance value between each wire: 0.05 - 0.5 ( )

2.

Insulation inspection of coil (insulation resistance gauge

500MV)
Check insulation between coil lead wire and core.
Standard:
1 M or more.

ROTOR
1. Inspection of slip ring (with vernier calipers and visual check)
Check the slip ring for wear and rough surface.
Standard:
Slip ring outer diameter:
Standard 22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
NOTE:

Only the slip ring cannot be replaced. Replace the rotor when
the rough surface cannot be repaired or the wear is exceeding
the limit.

Be careful not to damage the slip ring. Remove the dirt or foreign objects with compressed air or a clean cloth.

EE-14

ALTERNATOR
Inspection (Contd)
2.

Insulation inspection of rotor (insulation resistance gauge

500MV)
Check the insulation between slip ring and fan.
Standard:
1 M or more.

3. Resistance value inspection of coil (with circuit tester)

Measure resistance between slip rings.
Standard:
2.41 - 2.82

BEARING
Rotate bearing by hand.
Standard:
Check the bearing for noise, looseness, and grease
leakage (if it is a very small amount, only wipe it off). If it
is normal, bearing replacement is not necessary.
NOTE:
Do not reuse the bearing.

DIODE ASSEMBLY
1. Inspection of plus diode (with circuit tester)
Diode function check:
Check for continuity between the plus heat sink and each diode
terminal.
Standard:
Continuity exists in the forward direction. Continuity
should not exist in the reverse direction.
Diode is shorted when the continuity exists in both
directions.
Diode is opened when the continuity should not exist
in both directions.

EE-15

ALTERNATOR
Inspection (Contd)
2. Inspection of minus diode (with circuit tester)
Diode function check:
Check for continuity between the minus heat sink and each diode
terminal.
Standard:
Continuity exists in the forward direction. Continuity
should not exist in the reverse direction.
Diode is shorted when the continuity exists in both
directions.
Diode is opened when the continuity should not exist
in both directions.
3. Inspection of trio diode (with circuit tester)
Diode function check (3 small diode):
Check for continuity between each trio diode terminal.
Standard:
Continuity exists in the forward direction. Continuity
should not exist in the reverse direction.
Diode is shorted when the continuity exists in both
directions.
Diode is opened when the continuity should not exist
in both directions.

BRUSH
1.

Inspection of excessive length of brush (with vernier calipers

and scale).
Standard:
Excessive length of brush: 10 mm (0.39 in) or more.
Replace the brush set (brush, spring and terminal) if
it is under the standard.
2. Cleaning around the brush holder
Clean the brush and brush holder with clean cloth to remove the
abrasion powder.
3. Inspection of brush spring
Check if the brush moves smoothly and if there is no malfunction for
the spring pressure when sliding it in the brush holder.

REGULATOR (ON BOARD CHECK OF ALTERNATOR

COMPLETED PRODUCT)
1. Inspection of adjustment voltage
(a) Turn all electric load to OFF.
(b) Gradually raise the engine speed after checking that the value
of voltmeter is the overcharge voltage (15V) or less at idling.
(c) Always check that the voltmeter is not exceeding the
overcharge voltage, and then read the voltage (adjustment
voltage) when the engine speed reaches 2,500 rpm.
Standard:
14.50.3V
NOTE:
The measurement of ammeter should be the specified current (10A)
or less.
If it is the specified current or more, continue the charging for a while
and wait until it is the specified current or less.

EE-16

ALTERNATOR
Inspection (Contd)
2. Inspection of output current
(a) Turn all electric load to ON possible.
(b) Quickly read the maximum value of ammeter when the engine
speed raises 2,500 rpm or more.
Standard:
It should be 80% or more of 50A.
NOTE:
For the on board inspection, even if all electrical loads were used,
the current may not be beyond the official output current. It is normal
when there is 80% or more of official output.

EE-17