Servicing Starting System

COMPETENCY BASED LEARNING MATERIAL
Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Service Starting System
Module Title:
SERVICING STARTING SYSTEM
Technical Education and Skills Development Authority
East Service Road, South Superhighway, Taguig, Metro Manila
NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS
No. Unit of Competency Module Title Code

1. Service Starting System  Servicing Starting ALT723307
System
2. Service Charging System  Servicing Charging System ALT723308
3. Service Engine Mechanical  Servicing Cooling System ALT723309a
System  Servicing Lubricating System ALT723309b
 Servicing Gasoline Fuel System ALT723309c
 Servicing Air Induction System ALT723309d
 Servicing Diesel Fuel Injector ALT723309e
4. Service Clutch System  Servicing Clutch System ALT723310
5. Service Differential and Front  Servicing Differential and Front ALT723311
Axle Axle
6. Service Manual Steering System  Servicing Manual Steering ALT723312
System
7. Overhaul Manual Transmission  Pulling-out, Disassembling and ALT723313a
Checking Manual Transmission
 Assembling and Testing ALT723313b
Manual Transmission
8. Service Brake System  Identifying and Explaining ALT723314a
Hydraulic Brake System
Operations and Functions
 Servicing Brakes ALT723314b
 Overhauling Brake Systems ALT723314c
9. Service Suspension System  Servicing Suspension System ALT723315
How to use this Competency-Based Learning Material
Welcome to the Module Servicing Starting System. This module contains training
materials and activities for you to complete.
The unit of competency "Service Starting System" contains the knowledge, skills
and attitudes required for an Automotive Servicing. It is one of the specialized modules at
National Certificate II (NC II) level.
You are required to go through a series of learning activities in order to complete

each learning outcomes of the module. In each learning outcome there are Information
Sheets and Resource Sheets (Reference Materials for further reading to help you better
understand the required activities. Follow these activities on your own and answer the self-
check at the end of each learning outcome. You may remove a blank answer sheet at the
end of each module (or get one from your facilitator/trainer) to write your answers for each
self-check. If you have questions, don’t hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in this
learner's guide because you have:
 been working for some time
 already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular outcome,
you don't have to do the same training again.
Talk to your trainer about having them formally recognized. If you have a qualification
or Certificate of Competence from previous training, show it to you r trainer. If the skills you
acquired are still current and relevant to the unit/s of competency they may become part of
the evidence you can present for RPL. If you are not sure about the currency of your skills,
discuss this with your trainer.
After completing this module ask your trainer to assess your competency. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.
Inside this learner's guide you will find the activities for you to complete and at the
back are the relevant information sheets for each learning outcome. Each learning outcome
may have more than one learning activities.
At the back of this learner's guide is a Learner Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in providing
further details to your trainer or an assessor. A Record of Achievement is also provided for
your trainer to complete once you complete the module.
Program /Course Automotive Servicing NC II
Unit of Competency Service Starting System
Module Servicing Starting System
INTRODUCTION:
The starting system is a combination of mechanical and electrical parts that work
together to start the engine. A technician must be aware of the principles surrounding
the starting system in order to identify the source of the problem.
In this module you will learn how to test and repair starting systems/direct current
motors appropriate to vehicles. You will be performing activities to develop your skill in
testing starting system components and identify faults, disassemble starter,
repair/replace parts and reassemble starter components.
You will also review underpinning knowledge such as electrical principles, repair
procedures, electrical measuring and testing procedures and vehicle safety
requirements.
After doing the learning activities in this learner's guide you will be assessed by
your facilitator/instructor on repairing starting system, and direct current motors.
LEARNING OUTCOMES
Upon completion of this module you should be able to:
 Test starting system components and identify its faults;
 Disassemble starter motor; and
 Repair/Replace and assemble starter components/parts.
ASSESSMENT CRITERIA
All standard of performance for Repairing Starting Systems is in accordance with
company standard operating procedure and manufacturer’s specification Manuals using
specified tools and equipment.
1. Test starting system/components and identify faults:

1.1. Work is completed without causing damage to any workplace property or
vehicle.
1.2. Correct information is accessed and interpreted from appropriate
manufacturer specifications.
1.3. Tests are carried out to determine faults using appropriate tools and
techniques.
1.4. Faults are identified and preferred repair action is determined.
Code No. Date: Developed Date: Revised Page #

Module – Servicing Starting System
ALT723307 Aug. 15, 2003 1
2. Repair starting systems/direct current motors and/or associated
components
2.1. Starting systems/direct current motors are repaired without causing
damage to any workplace property or vehicle.
2.2. Correct information is accessed and interpreted from appropriate
manufacturer specifications.
2.3. Necessary repairs, component replacement and adjustments are carried
out using appropriate tools, techniques and materials.
PREREQUISITES
1. NC I certification
2. Modules on the following:

- Testing, Servicing and Replacing Automotive Battery
- Drawing/Reading Basic Technical Drawings
- Using and Maintaining Volt-Ohm Milliammeter
- Solving Basic Trade-Related Mathematics Problems

Module – Servicing Starting System
ALT723307 Aug. 15, 2003 2
LEARNING EXPERIENCES
Learning Outcome # 1 : TEST STARTING SYSTEM AND IDENTIFY FAULTS
Learning Activities Special Instructions
1. Identify starting system components,  Read Information Sheet # 1a

types and classification - Components and Functions of the
Starting System.
- Answer Activity #1a questions.
 Read Information Sheet # 1b -

- Starter Motor Operation.
- Answer Activity #1b questions.
 Read Information Sheet # 1c

- Types of Starter Motor.
- Answer Activity #1c question.
 Read Information Sheet # 1d.

- Classification of Starter Motor Drives
- Answer Activity #1d questions.
2. Scale reading of analog/digital  Follow procedures on Operation

Voltmeter/Ammeter Sheet # 2.
 Answer the Self-Check on pages 18-
19.
3. Conducting starting system
 Read the information on Activity # 3a.
components failure analysis
 Perform the procedures on Operation
Sheet # 3a.
 Read the Information Sheet # 3b.
 Read the information on Activity # 3b.
 Fill-up the Data table on page 34.
 Fill-up job-order form on page 35.
 Participate in a role play described on
Activity # 3d on page 38.

Servicing Starting System Aug. 15, 2003 3
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LO 1 - Test Starting System and Identify Faults
LEARNING OUTCOME 1:
At the end of these learning activities you should be able to test starting system
components and identify faults.
EQUIPMENT AND MATERIALS:
 Running condition engine

 Starting system (simulated mock-up)
 Multi-tester
 Service manual (Repair manual)
 Starter motor
 Set of wrenches
 Vernier caliper
 Sand paper
 Growler
LEARNING ACTIVITIES:
Activity # 1: IDENTIFY STARTING SYSTEM COMPONENTS, TYPES

AND CLASSIFICATION
Do you know the working components of the starting system and their
functions?
a. Read Information Sheet 1a, and then answer these questions.
 How does a starting motor operate?

 What are the types of starting motor and their working drive
mechanism?
b. Read Information Sheet 1b before answering these questions.
 Do you know how a starting motor operates?

 What are the principles involved in a motor operation?
c. Read Information Sheet 1c before answering this question.
 How is each type of starter motor differs from each other?
d. Read Information Sheet 1d before answering these questions.
 How are starter motor drives differs from each other according to
operation?
 What distinct type is commonly used at present?

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INFORMATION SHEET # 1a: COMPONENTS AND FUNCTIONS OF THE
STARTING SYSTEM
Starting the engine is possibly the most important function of the vehicle's electrical
system. The starting system performs this function by changing electrical energy from
the battery to mechanical energy in the starting motor. This motor then transfers the
mechanical energy, through gears, to the flywheel on the engine's crankshaft. During
cranking, the flywheel rotates and the air-fuel mixture is drawn into the cylinders,
compressed, and ignited to start the engine. Most engines require a cranking speed
of about 200 rpm.
Starting Systems
Two different starting systems are used on vehicles. Both systems have two separate
electrical circuits ... a control circuit and a motor circuit. One has a conventional
starting motor.
1. Automotive Battery - is a device that converts chemical energy into electric

energy. It supplies electric current to the starter motor and to the ignition switch
when the engine is being cranked.
2. Starting Motor -
is a device that
converts electric
energy into
mechanical
energy. It is
designed to
produce a large
amount of torque
for a short period
of time. It operates
when the ignition
switch is turned to
the start position.
Its purpose is to
crank the engine
for starting.
3. Starter Cables - a cable wiring that carries direct current from the battery to the
starting motor.
4. Ignition Switch - a mechanical switch which connect and controls electrical

current from the battery to the starting motor.
5. Fusible Link - a safety device installed in a circuit that interrupts short-circuit and
maintains constant flow of voltage.

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INFORMATION SHEET 1b: STARTER MOTOR OPERATION
1. CONVENTIONAL STARTER MOTOR
IGNITION SWITCH IN “ST”
 Current flows from the battery through

terminal “50” to the hold-in and pull-in
coils. Then, from the pull-in coil, current
flows through terminal “C” to the field
coils and armature coils.
 Voltage drop across the pull-in coil limits
the current to the motor, keeping its
speed low.
 The solenoid plunger pulls the drive
lever to mesh the pinion gear with the
ring gear.
 The screw spline and low motor speed
help the gears mesh smoothly.
PINION AND RING GEARS ENGAGED
 When the gears are meshed, the

contact plate on the plunger turns on the
main switch by closing the connection
between terminals “30” and “C.”
 More current goes to the motor and it
rotates with greater torque (cranking
power).
 Current no longer flows in the pull-in
coil. The plunger is held in position by
the hold-in coil's magnetic force.
IGNITION SWITCH IN “ON”
 Current no longer flows to terminal “50,”

but the main switch remains closed to
allow current flow from terminal “C”
through the pull-in coil to the hold-in coil.
 The magnetic fields in the two coils
cancel each other, and the plunger is
pulled back by the return spring.
 The high current to the motor is cut off
and the pinion gear disengages from the
ring gear.
 A spring-loaded brake stops the
armature.

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2. GEAR-REDUCTION STARTER MOTOR
IGNITION SWITCH IN “ST”
 Current flows from the battery through

terminal "50" to the hold-in and pull-in
coils. Then, from the pull-in coil, current
flows through terminal "C" to the field
coils and armature coils.
 Voltage drop across the pull-in coil
limits the current to the motor, keeping
its speed low.
 The magnetic switch plunger pushes
the pinion gear to mesh with the ring
gear.
 The screw and low motor speed help
the gears mesh smoothly.
PINION AND RING GEARS ENGAGED
 When the gears are meshed, the

contact plate on the plunger turns on the
main switch by closing the connection
between terminals “30” and “C.”
 More current goes to the motor and it
rotates with greater torque.
 Current no longer flows in the puff-in
coil. The plunger is held in position by
the hold-in coil's magnetic force.
IGNITION SWITCH IN “ON”
 Current no longer flows to terminal “50,”

but the main switch remains closed to
allow current flow from terminal “C”
through the pull-in coil to the hold-in coil.
 The magnetic fields in the two coils
cancel each other, and the plunger is
pulled back by the return spring.
 The high current to the motor is cut off
and the pinion gear disengages from the
ring gear.
 The armature has less inertia than the
one in a conventional starter. Friction
stops it, so a brake is not needed.

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INFORMATION SHEET 1c: TYPES OF STARTER MOTOR
1. CONVENTIONAL STARTER MOTOR

2. GEAR-REDUCTION STARTER MOTOR
3. PLANETARY-TYPE STARTER
The starter motors used on Toyota vehicles have a magnetic switch that shifts a rotating
gear (pinion gear) into and out of mesh with the ring gear on the engine flywheel. Two
types of motors are used: conventional and gear reduction. Both are rated by power
output in kilowatts (KW) ... the greater the output, the greater the cranking power.
CONVENTIONAL STARTER MOTOR
The conventional starter motor contains the components shown, The pinion gear is on
the same shaft as the motor armature and rotates at the same speed. A plunger in the
magnetic switch (solenoid) is connected to a shift lever. When activated by the
plunger, the shift lever pushes the pinion gear and causes it to mesh with the flywheel
ring gear. When the engine starts, an over-running clutch disengages the pinion gear
to prevent engine torque from ruining the starting motor.
This type of starter was used on most 1975 and older Toyota vehicles. It is currently
used on certain Tercel models. Typical output ratings are 0.8, 0.9, and 1.0KW. In most
cases, replacement starters for these older motors are gear-reduction motors.

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GEAR-REDUCTION STARTER MOTOR
The gear-reduction starter motor contains the components shown. This type of starter
has a compact, high-speed motor end a set of reduction gears. While the motor is
smaller and weighs less than conventional starting motors, it operates at higher speed.
The reduction gears transfer this torque to the pinion gear at 1/4 to 1/3 the motor speed.
The pinion gear still rotates faster than the gear on a conventional starter and with much
greater torque (cranking power).
The reduction gear is mounted on the same shaft as the pinion gear. And, unlike in the
conventional starter, the magnetic switch plunger acts directly on the pinion gear (not
through a drive lever) to push the gear into mesh with the ring gear.
This type of starter was first used on the 1973 Corona MKII with the 4M, six cylinder
engine. It is now used on most 1975 and newer Toyotas. Ratings range from 0.8KW on
most Tercels and some older models to as high as 2.5KW on the diesel Corolla, Camry
and Truck, The cold-weather package calls for a 1.4KW or 1.6KW starter, while a 1.0KW
starter is common on other models.
The gear-reduction starter (shown below) is the replacement starter for most
conventional starters.

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PLANETARY-TYPE STARTER MOTOR
The planetary type starter uses a

planetary gear to reduce the rotational
speed of the armature, as with the
reduction type, and the pinion gear
meshes with the ring gear via a drive
lever, as with the conventional type.
1. Speed Reduction Mechanism
Reduction of the armature shaft's

speed is accomplished by three
planetary gears and 1 internal gear.
When the armature shaft turns, the

planetary gears turn in the opposite
direction, which attempts to cause the
internal gear to turn. However, since
the internal gear is fixed, the
planetary gears themselves are
forced to rotate inside the internal
gear.
Since the planetary gears are

mounted on the planetary gear shaft,
the rotation of the planetary gears causes the planetary gear shaft to turn also. The
gear ratio of the armature shaft gear to the planetary gears and internal gear is
11:15:43, which results in a reduction ratio of approximately 5, reducing the rotational
speed of the pinion gear to approximately 1/5 of its original speed.
2. Damping Device
The internal gear is normally fixed,

but if too much torque is applied to
the starter, the internal gear is
caused to rotate, allowing the excess
torque to escape and preventing
damage to the armature and other
parts. The internal gear is engaged
with a clutch plate and the clutch
plate is pushed by a spring washer. If
excess torque is brought to bear on
the internal gear, the clutch plate
overcomes the pushing force of the
spring washer and turns, causing the internal gear to rotate. In this way, the excess
torque is absorbed.

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INFORMATION SHEET 1d: CLASSIFICATION OF STARTER MOTOR
DRIVES
1. Armature Shift Type
Both pinion and armature are

shifted into mesh with ring gear.
2. Inertia Drive Type
The pinion is fitted to the

armature shaft on which helical
splines are machined. In this
type, as the pinion rotational
inertia produces the difference
of revolutions between pinion
and armature shaft, the pinion
is slided on the helical splines
into mesh with ring gear.
3. Chain Drive Type
This type of starter is employed

for motor cycles and small
engines. The reduction device
is built-in. Starter pinion drives
the engine crank-shaft by the
chain. An over-running clutch is
installed on engine crank-shaft.
4. Starter-generator type
This type starter is employed for

motorcycles and small engines.
The armature is directly
connected into engine crank-
shaft. This type starter operates
as a starter only when starting
the engine, and operates as a
generator after the engine has
started.

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5. Magnetic switch type
This type starter is widely

used in recent automobiles.
Only the pinion with over-
running clutch is shifted by
solenoid-operated drive lever,
into mesh with the ring gear.
6. Reduction type starter
This newly developed starter

includes high-speed compact
motor and reduction gears.
The required torque is
obtained by reducing the
motor speed to approximately
one third.
The plunger in the magnetic

switch pushes the pinion
shaft through the plunger
shaft, and the pinion engages
with the ring gear.
The transition concerning the

ratio of output-to-weight is
shown in the chart.
It can be found the reduction

type starter presents an
outstanding improvement
with respect to the ratio of
output to weight.

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ASSESSMENT TASKS:
These assessment tasks should be completed when you are confident that you can
identify starter motor components, types and classification. Assessment needs to
conform to the rules of evidence. Therefore:
 You will need to participate and complete the learning activities
 You will demonstrate tasks to the required standard
 You will answer oral and written questions
 You will complete the assessment tool
OBSERVATION CHECKLIST:
Trainer’s check
Self
Component Competent Not yet
check
competent
System components and starter drive
properly identified.
Starter motor types and its operation properly

understood.
Utilized the service (repair) manual.

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Activity # 2: PREPARING REPAIR MANUAL AND VOM
SCALE READING OF ANALOG/DIGITAL VOLTMETER/AMMETER
Scale reading is very important in testing the starting system of automobile. The
problem can be identified using any of these instruments:
EQUIPMENT/INSTRUMENTS:
 Digital meter
 Analog meter
 Voltmeter
 Ammeter
 Ohmmeter
 Analog Multi meter
PARTS OF AN ANALOG TESTER
Ask your facilitator to provide you a working analog tester which you will use for this
activity. Observe the figure below and note the position of each part.
Note: The placement of parts on some testers may be different from the one shown
below, ask the facilitator to identify the equivalent parts.

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OPERATION SHEET # 2: MEASURING CURRENT, VOLTAGE AND
RESISTANCE
1. Turn the zero position adjuster so that the pointer may align right to the zero position.
2. Select a range proper for the item to be measured, set the range selector knob
accordingly.
NOTE: When determining a measuring range, select such one for higher voltage than
the value to be measured as well as where the pointer of a meter moves to a
considerable extent. However, select the maximum range and measure in case the
extent of value to be measured cannot be predicted.
MEASURING DCV (Direct Current Voltage)

1. Set the range selector knob to an appropriate DCV range.
2. Apply the black test pin to the minus potential of measured circuit and the red test pin
to the plus potential.
3. Read the move of the pointer to V and A scale.
(Refer to SCALE READINGS figure on page 17)
MEASURING ACV (Alternating Current Voltage)

1. Turn the range selector knob to an appropriate ACV range.
2. Apply the test leads to measured circuit.
3. Read the move of the pointer by V and A scale. (Use AC 10V scale for 10V range
only.)
 Since this instrument employs the mean value system for its AC voltage
measurement circuit, AC waveform other than sine wave may cause error.
 There occurs error under such frequencies other than specified in the
specification.
MEASURING DCA (Direct Current Amperes)

1. Turn the range selector knob to an appropriate DCA range.
2. Take out measured circuit and apply the black test pin to the minus potential of
measured circuit and the red test pin to the plus potential.
3. Read the move of the pointer by V and A scale.
MEASURING OHMS ()

NOTE: Do not measure resistance in a circuit where a voltage is present.
1. Turn the range selector knob to an appropriate  range.
2. Short the red and black test pins and turn the  adjustment so that the pointer may
align exactly to . (If the pointer fails to swing up to  even when the  adjuster is
turned clockwise fully, replace the internal battery with a fresh one.)
3. Apply the test pin to measured resistance.
4. Read the move of the pointer to  scale.
Note: The polarity of + and - turns reverse to that of the test leads when
measurement is done in  range.
How to replace battery

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1. Loosen the screws fixing the rear case and remove it.
2. Take out the battery and replace it with new.
3. Put back the rear case and fix it with the screws.
Note: Be sure to use the same type of battery to replace the drained one.
MEASURING CAPACITOR (C)

1. Set the range selector knob to C(F).
2. Measure the capacitance by applying the test pin to the capacitor to be measured
after  adjustment made in the same manner as in the resistance measurement.
3. The pointer moves full scale by the charge current to the capacitor. However, the
pointer starts gradual returning from a certain point. Read the then indicated
maximum value on C(F) scale.
Note: Be sure to short circuit both ends of the capacitor for discharge prior to the
initial measure after the measurement was once made.
Pay due attention to the polarity (+ and -) of the capacitor. (Connect + side of the
capacitor to - side of the tester.)
MEASURING AF OUTPUT (dB)

1. dB (decibel) is measured in the same way as ACV measurement reading the dB
scale instead. For measurement on the 10V range, the dB scale (-10dB - +22dB) is
read directly, but when measured on the 50V range, 14dB is added. On the 250V
range, 28dB is added.
Thus, the maximum dB readable is 22 + 40 = 62(dB) measured on the 1000V range.
Note: Cut direct current with a capacitor of 0.1F or more when measuring such
signal as having direct current.
MEASURING OF ICEO (Leak Current) FOR TRANSISTOR

1. Adjust 0 by setting the range selector knob to a proper range
from X1~X1k.
2. For NPN transistor, apply a black test pin to the collector and
the black one to the emmiter.
3. Determine the leak current by ICEO scale indicated on the
scale plate. (Unit in A, mA)

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MEASURING OF DIODE (Including LED)
1. Adjust 0 by setting the range selector knob to a

proper range from X1 (150mA)~ X100k (1.5A).
2. Apply the black test pin to anode side and the red one
to cathode side when measuring IF (forward current).
Apply the black test pin to cathode side and the red
one to anode side when measuring IR (reverse
current).
3. Read the indicated value by LI scale. (The pointer
moves to a considerable extent for IF, and little extent for IR)
4. Value indicated on LV scale during the measurement is the forward voltage of diode.
Note: Additional information is available in the supplemented Learning Element entitled

"Measuring Electrical Voltage Using a Multimeter".
SCALE READINGS
Range Multiplied Range Multiplied

 X 100K X 100K DCV 10 X1
X1k X1k 4 DCV 1000 X100
1
X10 X10 ACV 1000 X100
X1 X1 5 ACV 10 X1
DCV 250 X1 6 C (F) X1
DCV 2.5 X0.01 150mA at X1 X10 (mA)
DCV 0.25 X0.001 15mA at X10 X1 (mA)
7
2 ACV 250 X1 15A at X1k X10 (A)
DCA 0.25 X0.001 1.5A at X100k X0.1 (A)
DCA 25m X0.1 8 LV X1
DCA 2.5m X0.01 9 hFE X1
DCV 50 X1 ACV 10 X1
3 ACV 50 X1 ACV 50 14dB added
10
DCA 50 X1 ACV 250 28dB added
4 DCV 0.1 X0.01 ACV 1000 40dB added

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SELF-CHECK:
Read the instructions carefully, be sure to answer the questions fully before going to the
next activity.
Reading an Analog Multimeter
1. In the analog multimeter shown above, the range switch is set to take DC voltage
readings. Assuming that four different voltage measurements were taken (switch
positions 1, 2, 3, and 4) and the needle moved to the same position for each
measurement, the voltage readings would be as follows:
Setting 1: 1.85 V
Setting 2: 7.4 V
Setting 3: 37 V
Setting 4: 185 V
 Explain the significance of needle (pointer) movement of the multimeter.
 How do you detect if the battery of the multimeter is defective?
 What are the parts of the analog multimeter?
 What does it measure?
2. Determine the correct reading for each indicated position (1, 2, 3, and 4) of the
analog multimeter below.

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3. Convert each of the following digital multimeter readings.
a. 340 mV to volts
b. 0.75 V to millivolts
c. 2 A to milliamps
d. 1950 mA to amps
e. 7.5 ohms to kilohms
f. 2.2 kilohms to oms
g. 1.5 Megohms to ohms

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ASSESSMENT TASKS:
read analog/digital multimeter properly. Assessment needs to conform to the rules of
evidence. Therefore:
 You will answer oral and written questions (Self-Check)
Trainer’s check
Self
check
competent
Types of analog/digital voltmeter/ammeter
properly identified.
Analog/digital voltmeter/ammeter operation

properly understood.
Digital multimeter readings converted to
equivalent values

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Optional Activity:
Ask your instructor/facilitator to provide you the Starter Repair Manual and a VOM
to start working on Activity 3.
Parts of the Volt-Ohm Milliammeter (VOM)

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Activity # 3a: CONDUCTING STARTING SYSTEM COMPONENTS
FAILURE ANALYSIS
Starting problems can be classified into two broad categories:
 The engine cranks normally but fails to start.

 The cranking speed is too low to start the engine.
If the engine cranks normally but fails to start, the defect lies in the engine ignition,
fuel, or compression system. If the cranking speed is too low to start the engine, on
the other hand, the problem usually lies in the starting system though it could also lie
in the engine itself. At extremely low temperatures, for example, a much greater
torque is necessary to crank the engine because of higher oil viscosity.
In troubleshooting, careful observation of the conditions under which the trouble

arises will aid you greatly in accurately locating the source of the problem.
1. OUTLINE OF ON-VEHICLE INSPECTION

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If it is thought that the cause of
the trouble is not in the engine, but in In the case of vehicles with a
the starting system, first check to see clutch start system (manual
whether normal voltage is being transmission), a clutch starter relay
applied to the starter motor with the and clutch start switch are installed to
starter motor mounted in the vehicle. prevent starting if the clutch pedal is
not depressed.
Although the starter circuits
used on actual automobiles vary
in configuration from one model to
another, they may be roughly
broken down into two types: those
having a starter relay and those
without one. As the diagrams
illustrate, however, in both cases,
Terminal 30 always remains
connected to the battery while
Terminal 50 is connected only
when the ignition switch is in the
START position. The starter
circuit for automatic transmission
vehicles also has a neutral start
switch, which prevents the circuit
from closing, thus activating the
starter motor, unless the shift
lever is in the neutral (N) or park
(P) position.
Figure 1. Starting system circuit diagram

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Figure 2. Starting system circuit diagram with starter relay
*1 For automatic transmission vehicles
*2 For clutch start system
2. Turning the ignition switch to the START position causes the pinion gear to move
outward with a click, but the starter motor remains deactivated or does not speed
up.
The problem in this case probably lies in the starter motor, the engine itself, or in
the electrical system up to terminal 30.

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a. Check the engine rotational resistance. Check to see if unusually large torque
is required to crank the engine by rotating the crankshaft manually using a
box-end wrench, etc.
b. Measure the battery terminal voltage. When the ignition switch is in the START
position, the terminal voltage should be 9.6 V or higher.
If the measured value falls below this level, recharge or replace the battery.
Check for stains or corrosion on the battery terminals as well.
c. Measure the voltage between Terminal 30 of the starter motor and ground.
When the ignition switch is in the START position, the voltage should be 8 V or
higher. If the measured value falls below this level, check the starter cable
between the battery and Terminal 30 and repair or replace it if necessary.
d. Before disassembling the starter motor, roughly pinpoint the source of the
problem so that the job may proceed more smoothly. (In this case, the trouble
may originate with poor main switch contact, excessively large electrical
resistance between the brushes and the commutator, slipping of the starter
clutch, etc.)
ON-VEHICLE INSPECTION
 Make sure to put the shift lever in either the neutral (N) or the park (P)
position when checking an automatic transmission vehicle.
 In the case of vehicles with a clutch start system, check with the clutch
pedal depressed.

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CHECK BATTERY TERMINAL VOLTAGE
1. Turn the ignition switch to the START position and measure the voltage at the
battery terminals.
Standard 9.6 V or higher
2. Replace the battery if the voltage is lower than 9.6 V.
IMPORTANT:
 If the starter does not operate, or if
it turns slowly, be sure to check first
to see whether the battery is normal
or not.
 Even if the measured terminal

voltage is at the normal level,
stained or corroded terminals may
cause poor starting due to
increased resistance, leading to a
decrease in the voltage when the
ignition switch is turned to START
position.
CHECK TERMINAL 30 VOLTAGE
1. Turn the ignition switch to the START

position and measure the voltage
between starter terminal 30 and the
body.
Standard: 8.0 V or higher
2. Check the starter cable and repair or

replace it if necessary if the voltage is
lower than 8.0 V.
IMPORTANT!
Since the location and appearance of
Terminal 30 may differ depending on
the type of starter motor, make sure of
these by checking the repair manual.

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CHECK TERMINAL 50 VOLTAGE
1. Turn the ignition switch to START and

measure the voltage between starter
terminal 50 and the body.
Standard: 8.0 V or higher
2. If the voltage is lower than 8.0 V,

check the fusible link, ignition switch,
neutral start switch, starter relay clutch
starter switch, etc., one at a time,
referring to the wiring diagram. Repair
or replace any parts which are faulty.
IMPORTANT:
Since the location and appearance of

terminal 50 may differ depending on
the type of starter motor, make sure of
these by checking the repair manual.
CLUTCH STARTER RELAY
If the clutch start system is abnormal,

carry out the following checks and
adjustments.
INSPECTION OF STARTER RELAY
1. INSPECT CLUTCH STARTER

RELAY
NOTE: The relay is located in the No. 1

junction block in the left cowl side.
Inspect Relay Continuity
a) Using an ohmmeter, check that there

is continuity between terminals 1 and
3.
b) Check that there is no continuity

between terminals 2 and 4.

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If continuity is not as specified, replace
the relay.
Inspect Relay Operation
a) Apply battery voltage across

terminals 1 and 3.
b) Check that there is continuity

between terminals 2 and 4.
If operation is not as specified, replace the relay.

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OPERATION SHEET # 3a - PERFORM STARTER MOTOR TESTS
IMPORTANT:
 Before beginning to disassemble the starter motor first roughly pinpoint the source of
the problem by the performance test is recommended since it helps speed up the
overhaul, Also perform this test after assembly is completed to make sure that the
starter motor is operating correctly.
 The test procedures for the conventional and reduction type starter motors are
essentially the same. This section, therefore, discusses the conventional type only.
 Complete each test as quickly as possible (within approximately 3-5 seconds).
Otherwise, the coil in the starter motor may burnout.
1. PULL-IN TEST
(a) Disconnect the field coil lead
from Terminal C.
(b) Connect the battery to the
magnetic switch as shown.
Check that the pinion moves
outward.
If the pinion gear does not move
outward, check for damage to the
pub-in coil, sticking of the plunger,
and other possible causes.
2. HOLD-IN TEST
With the battery connected as above
and with the pinion out, disconnect
the negative lead from Terminal C.
Check that the pinion remains out. If
the pinion gear retracts, check for
damage to the hold-in coil, improper
grounding of the hold-in coil, and
other possible causes.
3. PINION RETURN TEST

Disconnect the negative lead from
the switch body. Check that the
pinion retracts. If the pinion gear
does not immediately retract, check
for fatigue of the return spring,
sticking of the plunger, and other
possible causes.

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4. CHECK PINION CLEARANCE
(EXCEPT REDUCTION TYPE)
(a) Connect the battery to the
magnetic switch as shown.
(b) Move the pinion gear toward the

armature to remove slack, then
measure the clearance between
the pinion end and stop collar.
Standard clearance: 0.1 - 0.4

mm
(0.004 -- 0.016 in.)
5. NO-LOAD TEST
(a) Securely fix the starter motor
with a vise, etc.
(b) Connect the field coil lead to
Terminal C. Make sure the lead
is not grounded.
(c) Connect the battery and
ammeter to the starter as shown.
(d) Check that the starter rotates
smoothly and steadily, and that
the pinion moves out.
(e) Check that the ammeter reads
the specified current. Specified
current: Less than 50 A at 11 V
IMPORTANT!
The amount of electrical current flowing through the circuit in the no-load test varies
depending with the starter motor, but as much as 200-300 amperes flows in some
starter motors. Refer beforehand to the vehicle's repair manual for the amount of
current and be sure to use an ammeter with the appropriate capacity. Be sure to use
heavy-duty cables as well.
(f) Check that the pinion gear retracts and the motor stops as soon as the cable is
disconnected from Terminal 50. (This is necessary only for the conventional type
starter motor.) If the motor does not stop immediately, the armature brake is
defective.
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INFORMATION SHEET 3b: USING THE VERNIER CALIPER
The Vernier caliper is a precision measuring instrument. It is used to measure internal

and external dimensions to an accuracy of 0.02mm (0.001"). Vernier calipers are
available in different sizes but the most common are the 150mm (6 inch) and 300mm (12
inch) calipers. The measuring range of these instruments can be up to 50mm (2") less
than the quoted size.
Parts of the Vernier Caliper
Clamping
The adjustable jaw of the Vernier caliper is locked in position by tightening the
clamping screw. The facility to lock the adjustable jaw is also of particular advantage
when a dimension has been gauged and removal of the Vernier caliper from the
workpiece may cause a movement of the adjustable jaw.
If the Vernier caliper is to be used as a fixed gauge, the caliper is pre-adjusted to the
specified dimension and locked into position.
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Always ensure that the clamping screws are released before attempting to move the
adjustable jaw.
Example 1, Measuring external dimensions on a small component.

The workpiece should be deburred and the Vernier caliper clamping screws unlocked.
1. Hold the Vernier caliper in the right hand as shown. Ensure that the clamping screws
are slack.
2. Slide the adjustable jaw away from the fixed jaw until the component slides in
between the jaws.
3. Slide the adjustable jaw towards the fixed jaw until the component is in contact with
the two jaws.
4. Lock the fine adjustment

clamp with the left hand.
Note: It may be necessary to rest the

component on the workbench to avoid
removing it from the jaws.
5. Move and rock the Vernier caliper while adjusting

the adjustable jaw against the component to find
the minimum dimension and to ensure that the
jaws are square to the component.
6. Lock the main clamping screw.
7. Check the 'feel' of the jaws against the component for

squareness.
8. Read the Vernier caliper.

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Example 2, Measuring internal dimension on a large component.
The workpiece should be deburred and the Vernier caliper clamping screws unlocked.
1. Hold the Vernier caliper in both hands as

shown. Ensure that the clamping screws are
slack.
2. Slide the adjustable jaw towards the fixed jaw

until the jaws slide in between the two faces to be
measured.
3. Hold fixed jaw firmly against the inside face.
4. Slide the adjustable jaw outwards towards the other

face.
5. Lock the fine adjustment clamp.
6. Rock the adjustable jaw against the component whilst adjusting the
adjustable jaw until the ,jaw passes against the component with a slight drag.
7. Lock the main clamping screw.
8. Check the feel of the jaws against the component.
9. Read the Vernier caliper.
10. Add the combined thickness of the nibs to the reading.
Note: When first using the instrument check the combined thickness of the nibs with
a micrometer.

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Reading the Vernier Caliper Scale (metric)
Note:
A magnifying glass is a useful aid for reading the Workings for the example
scales on a Vernier caliper accurately. shown
1. Determine the number of whole centimeters to the 3 cm= 30.00 mrn
left of the zero on the Vernier scale.
2. Determine the number of whole millimeters 9 mm =

between the last whole figure obtained in (1) and 9.0 mm
the zero on the Vernier scale.
3. Determine whether a 0.5 millimeter is between the

Yes =
last whole millimeter obtained in (2) and the zero 0.50 mm
on the Vernier scale.
4. Find the line on the Vernier scale that lines up

6
with a line on the main scale.
6 x .02 = .12mm
(a) If the Vernier scale has 25 divisions: multiply
the number by .02
(b) If the Vernier scale has 50 divisions: multiply

the number by .01.
TOTAL 39.62 mm

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Activity No. 3b: MEASURING CURRENT, VOLTAGE, RESISTANCE IN
SERIES, PARALLEL AND COMBINED SERIES-
PARALLEL
EQUIPMENT / RESOURCES:
 Voltmeter
 Ammeter
 Circuit board
 Battery (12 V)
 Conducting wire with alligator clip
 3 bulbs (2, 4 & 6)
At the end of these learning activities you should be able to measure current, voltage,
and resistance of electrical circuits.
1. Using the given

equipment/materials connect
the three bulbs in series.
(Refer to the diagram 1).
Diagram 1. Series Circuit

When the switch is closed what is the:
a) Total resistance of the circuit;

b) Current across each resistor and;
c) Voltage across each resistor;
d) Relationship between current voltage and resistance;
Data
Resistance () Voltage Current

(V) (A)
a.
b.
c.
d.

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2. Using the same equipment,
connect the 3 bulbs in parallel
and make the same
measurements.
Diagram 2. Parallel Circuit
3. Now connect the bulb in

series-parallel and repeat the
measurement.
Diagram 3. Series-Parallel Circuit
ASSESSMENT: (APPLICATION)
1. The courtesy light or dome light in a car is rated at 2.0 candle-power. Using a
12-volt car system, determine the current and resistance of the lamp.
2. Calculate the current and the resistance in a starter motor rated at 700 candle-
power and 12 volts.

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Activity No. 3c: FILLING-UP JOB-ORDER FORM
Indicating the proper data may help you as a technician to get additional information
about repairing a starting system. It is a must to get the following information.
Fill-up the needed data in the following form.
Customer’s Name: Date: Car No.

Street Address: Technician Name:
City Supervisor’s Name:
Fax/Cell/Tel no.:
Vehicle Identification Year: Make: Model:
Number:
Engine License Color Mileage:
Technician Findings & Recommendations:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
Date Accepted: ________________ Action Taken: ___________________________
Date Released: ________________ Signature of Technician: ___________________
Checked by:
________________________
Supervisor’s Signature

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ASSESSMENT:
Without looking back at the previous page, try to answer the following questions.
1. What are the data found in the job-order form?
2. Why is it very important for you as technician to fill-up this form?
3. Who is responsible for checking this job order form?
4. Why are your findings/recommendations important?

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Activity No. 3d: ROLE PLAY
Everyday we follow and give instructions. Instructions are given orally and in written
form. If the instructions are accurate and specific you can easily follow them.
1. Assuming that you are already a technician. Get a partner and act-out a situation;
one will act as the supervisor giving instructions to a technician in repairing a starting
motor.
2. Let each group write their dialogue, first, then call one group to represent while others
listen while answering the following questions:
 What were the instructions given to the technician to follow?
 Why did the technician follow the instructions easily?

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ASSESSMENT TASKS:
conduct starting system components failure analysis properly. Assessment needs to
conform to the rules of evidence. Therefore:
Trainer’s check
Self
check
competent
Starting problems identified and methods of
inspection properly understood.
Starting components properly checked.
Procedures in starter motor testing properly

understood and performed
Measurement of values using VOM correctly
performed and recorded
Job-order form properly filled-up
Participated in role play

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Learning Outcome # 2 : DISASSEMBLE STARTER MOTOR
2. Prepare tools, area and  Read instructions in Activity #1

tester/equipment needed
2a. Pull-out the starter motor  Study and perform Activity #2a
2b. Using floor jack and stands  Study and perform Activity #2b
3a. Disassemble the starter motor  Study and perform Activity #3a
3b. Parts and function of starter motor  Identify parts of the starter by writing
the numbered parts on the space
provided.
4. Perform starter motor  Perform Activity #4

inspection/measurement and record
reading

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LO2 - DISASSEMBLE STARTER MOTOR
LEARNING OUTCOME 2:
At the end of these learning activities you should be able to:

- prepare tools, area and tester/equipment needed;
- pull-out starter motor;
- disassemble a starter motor; and
- perform starter motor inspection/measurement and record readings
 Caliper/Outside micrometer
 Growler
 VOM
 Dial gauge with magnetic stand
 V-block
 Surface plate
 Spring scale
Activity No. 1 - PREPARE TOOLS, AREA AND TESTER/EQUIPMENT

NEEDED
1. For your safety, read Information Sheet on "Safety Precautions and Care in Using
Hand tools, Machines and Portable Electric Power Tools"
2. Also read the Learning Element on "Measuring Electrical Voltage Using a Multimeter"
Do the assignments at the end of the learning element.

Check your performance using the progress check.

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Activity No. 2a - PULL-OUT THE STARTER MOTOR
1. Review Learning Outcome 1, Learning Activity 1. Study the illustration to be familiar

with the location of the starter motor.
After taking a series of tests on starting motor and all the test conducted indicates
the starter motor must be removed, how would you perform pulling-out starter motor
from the system? What precautionary safety measures would you observe in
performing the task?
2. Prepare the necessary tools/equipment needed. There are two ways of pulling-out a
starter from the vehicle. Select from the available facilities in your workshop.
a. Using a lift (steps 3-12)
b. Using a floor jack and stands (refer to activity #2b on page 41)
3. Set the vehicle on a hoist lift.
4. Raise hoist lift for proper pad-to-frame contact.
5. Raise vehicle a few inches above the ground
Note: Shake vehicle while observing for signs of any movement if there are any
unusual noises or movement of the vehicle, lower it down and reset the pads, then
follow step #4.
6. Disconnect negative cable clamp of the battery.
7. Disconnect positive cable and lead wire from the magnetic switch terminal.
8. Raise vehicle at the desired height and lock the hoist.
Caution: Do not get under the vehicle until the hoist lock has been set.
9. Loosen the starter mounting bolts and remove all but one.
Caution: The starter motor is heavy, make sure it is secured and supported before
removing the last bolt.
10. Support the starter motor and remove the remaining bolt.
11. Remove the starter motor.
12. Release the hoist lock and lower the vehicle.

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Activity No. 2b - USING FLOOR JACK AND STANDS
Have you checked the condition of the floor jack? Does it have sufficient rating to lift and
sustain the weight of the vehicle. Have you inspected for proper lubrication and hydraulic
fluid level? What course of action will you do if the jack does not pass any one of these
inspections? What is your recommendation?
1. Prepare the necessary tools/equipment needed.
2. Move the vehicle to a flat and level ground.
3. Shift the vehicle's transmission to

NEUTRAL for an automatic feed
transmission. Shift the
transmission to first gear on
vehicle with manual transmission.
4. Set the parking brake.
5. Place wheel blocks

around the rear
wheels.
6. Position the floor jack under the

front of the vehicle at a location
strong enough to support the
weight.
Note: The jack should be

centered between the front tires
and positioned so that the lift will
be straight up and down.
Caution: (Do not lift the front-

two-wheels of the vehicle too
high that it can slip off of the jack
saddle.)
7. Operate the jack until the jack

saddle contacts the lift points.

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Note: (Check for good contact if things look good, lift the front of the vehicle a couple
of inches off the floor. Recheck the position of the jack.)
8. Disconnect the negative cable clamp of the battery.
9. Disconnect positive lead wire from the magnetic

switch upper terminal.
10. Raise the vehicle to the required height.
11. Place two safety stands under the vehicle in a

location that will support the weight.
12. Slowly lower the vehicle onto the stands.
Caution: (Make sure the safety stands are located where they will not lean or slip).
13. Get beneath the vehicle using a creeper and locate the starter motor.
14. Loosen the starter mounting bolts and remove all but one.
Caution: (The starter motor is heavy, make sure it is secured before removing the
last bolt).
15. Support the starter motor and remove the remaining bolt.
16. Pull-out the starter motor.

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Activity No. 3a - DISASSEMBLE STARTER MOTOR
CONVENTIONAL STARTER MOTOR
Components of a Conventional Type Starter Motor
Procedure:
1. Prepare the necessary tools needed.
2. Disconnect the lead wire from the magnetic

switch lower terminal.

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3. Loosen two screws , unhook the moving
stud from the drive lever by tilting the switch
end as shown and pull out the magnetic
switch.
4. Remove the end frame cover, armature shaft

lock plate, brake spring and rubber ring.
5. Separate the commutator end frame from

the yoke by removing two through bolts.
6. Take off the brushes and pull out the brush

holder from the armature shaft.

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7. Separate the yoke from the drive housing
8. Remove the drive lever set bolt, then take

off the rubber and plate from the drive
housing.
Pull out the armature with overrunning clutch

and drive lever.
9. Tap in the stop collar, using a socket

wrench. Then take off the pinion after
removing snap ring.
10. Remove the snap ring, using a snap ring

expander.

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REDUCTION TYPE STARTER MOTOR
Components of a Reduction Type Starter Motor
Note: The procedure in disassembling reduction type starter motor is similar to the
conventional type.
Procedure:
1. Disconnect the lead wires from magnetic switch.

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2. Remove two through bolts from motor side front
housing.
3. Slightly tap on the motor housing with a plastic

hammer, then separate the motor component
from magnetic switch.
4. Remove two screws from drive end frame.
5. Separate the front housing from magnetic switch

housing.

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6. Pull out the overrunning clutch assembly.
Caution: Be careful not to lose a steel ball

located between magnetic switch and
overrunning clutch.
7. Remove the drive pinion and idle gear.
8. Remove the brushes from brush holder, then pull

out the armature from yoke.
Caution:
a. Magnetic switch assembly must not be

disassembled, especially three screws
indicated by arrows must not be loosened or
tightened.
b. The hexa-nuts on terminal bolts must not be
loosened.

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PLANETARY TYPE STARTER MOTOR
Components of a Planetary Type Starter Motor
Procedure:
1. REMOVE MAGNETIC SWITCH

(a) Remove the nut, and disconnect the lead
wire from the magnetic switch terminal.
(b) Loosen the two nuts holding the magnetic
switch to the drive housing.
(c) Pull the magnetic switch and while lifting
the front part of the magnetic switch,
release the plunger hook from the
drive lever, then release the magnetic
switch.
(d) Remove the plunger cover.
2. REMOVE PLANET CARRIER SHAFT AND

INTERNAL GEAR
(a) Using snap ring pliers, remove the snap
ring and plate washer.
(b) Remove the planet carrier shaft and plate
washer.

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Activity No. 3b - PARTS AND FUNCTIONS OF STARTER MOTOR
After you have disassembled the starter motor and the disassembly of parts are
arranged in numerical order, you are ready to identify the parts and sequentially state the
function of each part. You may use the Parts Identification Sheet showing the
disassembled parts in numerical order. Identify each part indicated by the arrow on the
numbered spaces. Review your answers and compare them with that on page 69 of this
LO.
Common parts of a starter motor:
1. Starter housing or starter frame - the outer portion of a starter motor.
2. Armature - consists of a stock of iron laminations located over a steel shaft, a

commutator assembly, and the armature windings.
3. Brushes - small blocks of carbon that contacts with the commutator and conducts
electric current to the armature.
4. Starter drive mechanism - part of the starting system that connects the motor
armature to the flywheel ring gear.
5. Magnetic switch - engages the pinion gear into the ring gear and switches current to
the motor.

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PARTS IDENTIFICATION SHEET
1. 9.
2. 10.
3. 11.
4. 12.
5. 13.
6. 14.
7. 15.
8.

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Activity No. 4 - PERFORM STARTER MOTOR INSPECTION/
MEASUREMENT AND RECORD READING
A. CONVENTIONAL STARTER MOTOR.
Armature
Inspect the following items and repair or replace if necessary
1. Clearance between shaft and bearing: If over

the limit, replace the bearing.
Clearance limit: 0.2 mm (0.008 in.)
- Bush replacement
(a) Replace the bush by using a suitable tool

as shown.
(b) After installing a new bush, ream it to

obtain 0.05 mm (0.0020 in.) oil clearance.
(c) When assembling, apply the

recommended grease.
2. Armature short circuit test
Place the armature on the armature tester and

hold a steel strip against the armature core
while turning the armature.
If the steel strip is attracted or vibrates, the

armature is shorted and must be replaced or
repaired.
- Following tests can be performed with a circuit

tester.

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3. Armature coil ground test
Touch one probe to the commutator segment and the other probe to the armature
core. There should be no continuity. If there is continuity, the armature is grounded.
Replace the armature if grounded.
4. Armature coil continuity test
Touch the probes to two of segments. There

should be continuity. If there is no continuity at
any test points, the coil is open-circuited.
Replace the armature if open-circuited.
Commutator
Inspect for the following items and repair or replace if necessary.
1. Visual check:
Check the commutator for dirty or burnt

surface and correct by sandpaper or lathe if
necessary.
Use #400 sandpaper when correct.
2. Run-out:
Correct on a lathe if it exceeds the limit.

Run-out limit = 0.4 mm (0.016 in.)
Standard = 0.05 mm (0.0020 in.)
Correcting limit is to be within 2 mm.
3. Depth of segment mica:
Correct if less than the limit.

Limit = 0.2 mm (0.008 in.)
Standard = 0.5 to 0.8 mm
(0.020 to 0.032 in.)

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Yoke
1. Visual check
Check the field coil for wear or damage. Replace

the field coil by removing pole core screws if
necessary.
Note: For directly-wound type field coil, replace

it as a yoke assembly.
2. Field coil ground test
Circuit tester can be used.
Touch one probe to the field coil end and the

other probe to the bare surface of the yoke
body.
There should be no continuity. If there is

continuity, the field coil is grounded. Make
necessary repairs if grounded.
3. Field coil continuity test
Circuit tester can be used.

Touch one probe to the lead wire and the other
probe to the field coil brush. There should be
continuity. If there is no continuity, the field coil
is open-circuited. Replace the field coil if open-
circuited.
Brush and brush holder
1. Brush length
Measure the brush length and replace if the brush is

worn by a third (1/2) of its original length.

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2. Brush replacement
When necessary to replace the negative side

brush installed on the brush holder, replace the
brush holder as an assembly because the brushes
are welded. For the field coil brush, solder the
brush lead firmly.
Note: For the heavy duty designed type starter,
replace the individual brush by loosening the
tightening screw.
3. Brush holder insulation test
This test can be performed with a circuit tester.
Touch one probe to the negative brush holder and

the other probe to the positive brush holder. There
should be no continuity.
If a continuity is indicated, repair or replace.
4. Inspect the brush spring tension
The brush spring tension should satisfy the

specification. Usually its tension is around 1200
grams. (2.64 lb).
Overrunning clutch and pinion gear
1. Inspect the spline teeth for wear and damage.

Replace if necessary.
2. Inspect the spline tube for smooth movement.

Repair or replace movement.

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3. The pinion should be rotated free in a clockwise
direction. And in a counterclockwise direction the
pinion should be locked.
Drive lever
Inspect the drive lever and spring for wear and

replace if necessary.
Magnetic switch
1. Pull-in test
Connect the magnetic switch to battery as

shown. (negative side to "C" terminal and switch
body; positive side to "50" terminal). If the pinion
has definitely jumped out, the pull-in coil is
satisfactory.
2. Hold-in test
Next disconnect the "C" terminal

The pinion should remain in jumped-out
condition.
3. Check the plunger return
When disconnecting the switch body, the pinion

should return quickly.

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B. REDUCTION TYPE STARTER MOTOR.
Armature
1. Armature short-circuit test
Place the armature on the armature tester and

hold a steel strip against the armature core while
turning the armature.
If the steel strip is attracted or vibrates, the

armature is shorted and must be replaced or
repaired,
Following tests can be performed with a circuit tester.
2. Armature coil ground test
Touch one probe to the commutator segment

and the other probe to the armature core. There
should be no continuity. If there is a continuity,
the armature is grounded.
Replace the armature if grounded.
3. Armature coil continuity test
Touch the probes to two of segments. There

should be continuity.
If there is no continuity at any test points, the

coil is open-circuited.
Commutator
1. Visual check:
Check the commutator. for dirty or burnt surface

and correct by sandpaper or lathe if necessary.
Use #400 sandpaper when correct.

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2. Run-out:
Correct on a lathe if it exceeds the limit.
Run-out limit = 0.4 mm (0016 in.)
Standard = 0.05 mm (0.0020 in.)
Correcting limit is to be within 1 mm.
3. Depth of segment mica:

Correct if less than the limit.
Limit = 0.2 mm (0.008 in.)
Standard = O.5 to 0.8 mm
(0.020 to 0.032 in)
Correct with an undercutting machine or
equivalent.
After correcting, eliminate chips using

sandpaper.
Yoke
1. Field coil ground test

Touch one probe to the field coil end and the
other probe to the bare surface of yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
Make necessary repairs if grounded. If there is
still continuity, the field coil should be replaced.
2. Field coil continuity test
Touch one probe to the lead wire and the other

probe to the field coil brush.
There should be continuity. If there is no
continuity, the field coil is open-circuited.
Replace the field coil if open-circuited.

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Brush & brush holder
1. Brush length
Measure the brush length and replace if the

brush is worn by a third (1/3) of its original
length.
2. When necessary to replace the negative side

brush installed on the brush holder, replace
the brush holder as an assembly because the
brushes are welded.
For the field coil brushes, if the brushes are

worn by a third of its original length, replace
the brushes as motor assembly because these
brushes are also welded.
3. Brush holder insulation test

This test can be performed with a circuit tester.
Touch one probe to the negative brush holder

and the other probe to the positive brush
holder. Repair or replace if a continuity is
indicated.
4. Inspect the brush spring tension
The brush spring tension should meet its

specification. Usually its tension is around 1500
grams (3.307 Ib)

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Over-running Clutch
1. Check the pinion for wear and damage.
2. Check the ball bearing for smooth rotation.
3. The pinion should be rotated free in a

clockwise direction. And in a counterclockwise
direction the pinion should be locked.

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Magnetic switch
Caution: Pull-in and Hold-in tests must be

performed in short time (3-5 seconds) to prevent
the coil from burning.
1. Pull-in test
Impress 12V between magnetic switch ST and

main terminals, and also switch body. If the
plunger jumps out firmly, the pull-in coil is
satisfactory. If defective, replace the magnetic
switch.
2. Hold-in test
Next, disconnect from the main terminal. At this

time, the plunger should still be jumped out. If
defective, replace the magnetic switch.
3. At above state, check for continuity between the

main and IG terminals.
If there is no continuity, replace the magnetic
switch.

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C. PLANETARY TYPE STARTER MOTOR
This section describes the procedure only for those portions which differ from the
conventional and reduction type.
Planet Carrier Shaft and Center Bearing
1. INSPECT PLANET CARRIER SHAFT AND

CENTER BEARING
(a) Using a micrometer, measure the outer
diameter of the surface in contact with the
center bearing of the plant carrier shaft.
Standard shaft diameter:

14.035 -- 15.000 mm (0.5526 -- 0.5906
in.)
(b) Using a caliper gauge, measure the inside

diameter of the center bearing.
Center bearing inside diameter:
15.000 -- 15.035 mm (0.5906 --
0.5919 in.)
(c) Subtract the planet carrier shaft diameter
from the bearing inside diameter
measurement.
Standard center bearing oil clearance:
0.03 mm (0.0012 in.)
Maximum center bearing oil clearance:
0.1 mm (0.004 in.)
If the clearance is greater than maximum,
replace the planet carrier shaft and center
bearing.
2. IF NECESSARY, REPLACE CENTER

BEARING
(a) Using SST and a press, press out the
center bearing.
SST 09221-25024 (09221-00090)
(b) Using SST and a press, press in a new

center bearing to the position shown in
the illustration.
SST 09221-25024 (09221-00090)

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STARTING MOTOR INSPECTION AND MEASUREMENT CHECKLIST
Name:________________________________________ Date: __________________
Group No.: _______________
1. Check pull-in coil
OK NOT OK IF NOT OK, WHY?
2. Check hold-in coil
3. Perform return test on solenoid switch
4. Check armature shaft to bushing clearance

(Standard: 0.05 mm, Limit: 0.2 mm

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5. Check starter drive housing for cracks/damage
6. Check overrunning clutch
7. Check commutator run-out

Standard: 01.1 mm, Limit: 0.3 mm
8. Check armature for ground
9. Check armature for short circuit

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10. Check armature for open circuit
11. Check depth of mica segment

Standard: 0.5 - 0.8 mm, Limit: 0.2 mm
12. Check field frame (housing) for cracks/damage
13. Check pole shoe/s for looseness
14. Check field coil for open circuit

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15. Check field coil for grounded circuit
16. Measure brush length. Limit: 12 mm
17. Check insulated brush holder for grounded

circuit
18. Check brush spring/s for cracks/damage
19. Check armature thrust clearance

Limit: 088 mm

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20. Check pinion gap - 02 -2.5 mm
21. Perform starter no-load test

Starter test voltage = 11 volts
Starter current draw = 40 - 60 amperes

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Learning Outcome # 3 : REPAIR/REPLACE AND ASSEMBLE STARTER
1. Prepare supplies, materials, tools and

equipment
2. Repair/Replace starter motor  Study the procedure and perform

Activity #2
 Study the procedure and perform

3. Reassemble starter motor
Activity #3.
Note: Reassembly will be done using
the previous type of starter
disassembled.
 Fill-up the form on page 80. Have it

4. Test the starter motor and record
signed by your facilitator/instructor.
findings
5. Install starter motor and re-check  Study the procedure and perform
serviceability Activity #5
 Evaluate the performance of the

starter motor by comparing your
findings with the table on Information
Sheet 5a.
 Perform the following tests described

in Information Sheet 5b and 5c.

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LO3 - REPAIR/REPLACE AND ASSEMBLE STARTER
LEARNING OUTCOME 3:
At the end of these learning activities you should be able to:

- prepare supplies and materials, tools, tester/equipment needed;
- repair/replace starting motor parts;
a. replace starter bushing/bearing
b. replace starter brushes
c. replace starter drive gear
- reassemble the unit; and
- install starting motor and re-check serviceability.
 Tool box
 Jack
 Safety stands
 Creeper
 Starter repair kit
 Multimeter
 Sandpaper #400
 Safety glasses
Activity No. 1 - PREPARE SUPPLIES, MATERIALS, TOOLS AND

EQUIPMENT
1. For your safety, read Information Sheet on "Safety Precautions and Care in Using
Jacks"
Activity No. 2 - REPAIRING/REPLACING STARTER MOTOR
a. Repairing Commutator
Check the following items and repair or

replace as necessary.
1. Dirty or burnt surface
Correct with sandpaper if necessary

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2. Depth of segment mica.
Mica depth:
STD 0.45 - 0.75 mm
(0.0177 - 0.0295 in.)
Limit 0.2 mm
(0.008 in.)
3. Repair the segment mica.

(1) If the mica depth is below the limit,
correct with a hacksaw blade.
(2) Smooth out the edge with a

hacksaw blade.
(3) Use #400 sandpaper to smooth

the commutator surface.

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b. Replacing Bushing/Bearing
a.1 Replacing Bushing
Replace the bush by using a suitable

tool.
After installing a new bush, ream it to

obtain 0.05 mm (0.0020 in.) oil
clearance.
When assembling, apply the recommended grease.
a.2 Replacing Bearing
Using SST, remove the bearing from the

armature shaft.
Using SST, remove the other bearing on

the opposite side.
SST 09286-46011
Using SST and a press, press a new

large bearing onto the shaft.
SST 09285-76010 (USA & Canada, 1.0

kW)
SST 09201-41020 (Other than above)
Using a press, install a new small

bearing onto the shaft.
c. Replacing Brushes
Measure the brush length and replace if the

brush is worn by a third (1/3 of its original
length.

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When necessary to replace the negative side
brush installed on the brush holder, replace
the brush holder as an assembly because the
brushes are welded. For the field coil brush,
solder the brush lead firmly.
Note: For the heavy duty designed type
starter, replace the individual brush by
loosening the tightening screw.
d. Replacing Starter drive gear
Inspect the spline teeth for wear and

damage. Replace if necessary.
Inspect the spline tube for smooth movement.

Repair or replace if necessary.
The pinion should be rotated free in a

clockwise direction. And in a
counterclockwise direction the pinion should
be locked.

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Activity No. 3 - REASSEMBLE STARTER MOTOR
Follow the disassembling procedures in the reverse order. However attention should
be paid on the following operation.
CONVENTIONAL TYPE (Reassembly)
1. INSTALL STARTER CLUTCH ONTO

ARMATURE
(a) Place a new stop collar on the armature.
(b) Drive in the snap ring with a 14 mm (0.55

in.) socket wrench, then fit it into the shaft
groove.
(c) Using-a vise, compress the snap ring.

Make sure that the snap ring fits correctly.
(d) Using a screwdriver,-tap the pinion to

slide the stop collar onto the snap ring.
(e) Assemble the drive lever in the direction

as shown.
(f) After installation, position the brush

holder as shown.

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(g) Install washer, brake spring and lock
plate. Then measure the armature shaft
clearance. If the clearance exceeds the
specified value, correct by increasing the
number of shims.
(h) Supply the end frame cap with

recommended grease before installing it
on commutator end frame.
(i) Hook magnetic switch joint on drive

lever spring correctly.

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REDUCTION TYPE (Reassembly)
Follow the disassembling procedures in the

reverse order. However, attention should be paid
on the following operations.
1. Install the brush holder, aligning its tab with

notch in the yoke frame.
2. When installing the brush and brush holder,

take care that the (+) lead wires are not to
damage them.
3. Fit the felt wick oiler onto the armature shaft,

and O-ring to the yoke frame.
4. Face the field coil lead wire towards the

magnetic switch, and install the field frame with
armature, aligning the bolt anchors with mark
on the magnetic switch.
5. Apply the recommended grease, install the

steel ball into the clutch shaft hole.

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PLANETARY TYPE STARTER MOTOR (Reassembly)
1. INSTALL INTERNAL GEAR AND PLANET

CARRIER SHAFT
(a) Apply grease to the internal gear touching

the shock absorber and planetary gears.
(b) Align the hollow of the internal gear with the

protrusion inside the shock absorber.
(c) Insert and turn the internal gear so that it

interlocks with the shock absorber.
2. INSTALL STARTER CLUTCH
(a) Apply grease to the bushing and spline of

the starter clutch stop collar.
(b) Place the starter clutch and stop collar on

the planet carrier shaft.
(c) Apply grease to the snap ring, and install it

to the planet carrier shaft groove.
(d) Using a vise, compress the snap ring.
(e) Hold the starter clutch, tap the planet carrier

shaft and install the stop collar onto the snap
ring with a plastic-faced hammer.

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Activity No. 4 - TEST AND RECORD FINDINGS FOR SERVICEABILITY
1. Test the newly assembled starter motor and fill-up the form below.
Customer’s Name: Date: Car No.

Street Address: Technician Name:
City Supervisor’s Name:
Fax/Cell/Tel no.:
Vehicle Identification Year: Make: Model:
Number:
Engine License Color Mileage:
Technician Findings & Recommendations:
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
Date Accepted: ________________ Action Taken: ___________________________
Date Released: ________________ Signature of Technician: ___________________
Checked by:
________________________
Supervisor’s Signature

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Activity No. 5 - INSTALL STARTER MOTOR AND RE-CHECK
SERVICEABILITY
Caution: Transmission is shifted to PARK position for automatic and NEUTRAL

position for manual transmission. Check that wheel chucks are placed in front and
rear of the wheel.
Note: Review the procedures in LO 2, Activity 2a, Pulling out the starter motor using
Hoist Lift (page 42) or Activity 2b, Using Floor Jack and Stands in installing starter
motor (pages 43-44).
1. Insert starting motor to mounting hole. Screw hold-down bolt by hand.
Tighten bolts observing the proper sequence, pattern and torque per repair
manual instruction and specification.
2. Connect starting motor wire and cables.
3. Connect battery post clamp, positive first before the negative post clamp.
Read Information Sheet 5a "Diagnosis and Testing."
4. Perform current draw test.

Read Information Sheet 5b to learn the procedure of current-draw testing.
5. Perform voltage drop test.
a) motor circuit
b) control circuit

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INFORMATION SHEET 5a. DIAGNOSIS AND TESTING
The starting system requires little maintenance. Simply keep the battery fully charged
and all electrical connections clean and tight.
Diagnosis of starting system problems is relatively easy. The system combines

electrical and mechanical components. The cause of starting may be electrical (e.g.,
faulty switch) or mechanical (e.g., wrong engine oil or a faulty flywheel ring gear).
Specific symptoms of starting system problems include:
 The engine will not crank;
 The engine cranks slowly;
 The starter keeps running;
 The starter spins, but the engine will not crank; and
 The starter does not engage or disengage or disengage properly.
For each of these problems, refer to the chart below for possible causes and needed
actions. Diagnosis starts with a thorough visual inspection. Testing included: a starter
motor current draw test, starter circuit voltage drop tests, operational and continuity
checks of control components, and starter motor bench tests.
SYMPTOM POSSIBLE CAUSE ACTION NEEDED

Engine will not crank  Dead battery  Check battery
 Melted fusible link  Replace fusible link
 Loose connections  Clean and tighten connections
 Faulty ignition switch  Check switch operation; replace as
needed
 Faulty magnetic switch, relay,  Check and replace as needed
neutral start or clutch switch
 Mechanical problem in engine  Check engine
 Problem in theft deterrent system  Check service manual for system
tests
SYMPTOM POSSIBLE CAUSE ACTION NEEDED
Engine cranks too  Weak battery  Check battery and charge as
slowly to start
 Loose or corroded connections needed
 Faulty starter motor  Clean and tighten connections
 Mechanical problems with engine  Test starter
or starter  Check engine and starter; replace
worn out parts
Starter keeps running  Damaged pinion or ring gear  Check gears for wear or damage
 Faulty plunger in magnetic switch  Test starter pull-in and hold-in coils
 Faulty ignition switch or control  Check switch and circuit
circuit components
 Binding ignition key  Check key for damage
Starter spins, but  Faulty over-running clutch  Check over-running clutch for
engine will not crank
 Damaged or worn pinion gear or proper operation
ring gear  Check gears for damage and wear;
replace as needed
Starter does not  Faulty magnetic switch  Bench test starter
engage/disengage
properly
 Damaged or worn pinion gear or  Check gears for damage and wear;
ring gear replace as needed

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INFORMATION SHEET 5b. CURRENT DRAW TEST
A starter current draw test provides a quick check of the entire starting system. With
the Sun VAT-40 tester, it also check battery's cranking voltage. If another type of tester is
used, follow the manufacturer's recommended procedure.
The starting current draw and cranking voltage should meet the specifications listed
in the vehicle model being tested. Typical current draw specs are 130-150 amps for 4-
cylinder models and 175 amps for 6-cylinder models. Cranking voltage specs range from
9.6 to 11 volts. Always refer to the correct repair manual. Only perform the test with the
engine at operating temperature.
The following steps outline a typical procedure for performing a current draw test on a
starting system:
1. This test should be made only with a serviceable battery. The specific gravity
readings at 800F should average at least 1.190 (50% charged). Charge the battery,
if necessary.
2. Prepare the tester.

 Rotate the Load Increase control to OFF.
 Check each meter's mechanical zero. Adjust if necessary.
 Connect the tester Load Leads to the battery terminals; RED to positive, BLACK
to negative.
NOTE: Battery open-circuit voltage should be at least 12.2 volts (50% charged). If not,
the battery requires charging.
 Set Volt Selector to INT 18V. Tester voltmeter should indicate battery open-circuit
voltage.
 Set Test Selector to #2 CHARGING.
 Adjust ammeter to read ZERO using the electrical Zero Adjust control.
3. Connect the clamp-on Amps Pickup around the battery ground cable or cables.
4. Make sure all lights and accessories are off and vehicle doors are closed.
5. Set the Test Selector switch to #1 STARTING.
6. Disable the ignition so the engine does not start during testing.
7. Crank the engine, while observing the tester ammeter and voltmeter.
 Cranking speed should be normal (200-250 rpm).
 Current draw should not exceed the maximum specified.
 Cranking voltage should be at or above the minimum specified.
8. Restore the engine to starting condition and remove tester leads.

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TEST RESULTS: High current draw and low cranking speed usually indicate a faulty
starter. High current draw may also be caused by engine problems. A low cranking
speed with low current draw, but high cranking voltage, usually indicates excessive
resistance in the starter circuit. Remember that the battery must be fully charged and its
connections tight to insure accurate results.

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INFORMATION SHEET 5c. VOLTAGE-DROP TEST
Voltage-drop testing can detect excessive resistance in the starting system. High
resistance in the starter motor circuit (power side or ground side) will reduce current to
the starting motor. This can cause slow cranking speed and hard starting. High
resistance in the starter control circuit will reduce current to the magnetic switch. This
can cause improper operation or no operation at all.
A Sun-VAT-40 tester or separate voltmeter can be used. The following steps outline a
typical procedure for performing voltage-drop tests on the starting system:
Motor Circuit (Insulated Side)
1. If using the Sun VAT-40, set the Volt Selector to EXT 3V. For other voltmeters, use a
low scale.
2. Connect the voltmeter leads ... RED to the battery positive (+) terminal, BLACK to
terminal "C" on the starter motor magnetic switch.
3. Disable the ignition so the engine cannot start during testing.
NOTE: On models with the Integrated Ignition Assembly, disconnect the "IIA" plug. On
others, disconnect the power plug to the remote igniter assembly (black-orange wire).
4. Crank the engine and observe the voltmeter. Less than 0.5 volt indicates acceptable
resistance. More than 0.5 volt indicates excessive resistance. This could be caused
by a damaged cable, poor connections, or a defective magnetic switch.
5. If excessive resistance
is indicated, locate the
cause. Acceptable
voltage drops are 0.3
volt across the
magnetic switch, 0.2
volts for the cable, and
zero volts for the cable
connection. Repair or
replace components as
needed.

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MOTOR CIRCUIT (Ground Side)
1. Connect the voltmeter leads ... RED to the starter motor housing, BLACK to the
battery ground (-) terminal.
2. Crank the engine and observe the voltmeter. Less than 0.2 volt indicates acceptable
resistance. More than 0.2 volt indicates excessive resistance. This could be caused
by a loose motor mount, a bad battery ground, or a loose connection. Repair or
replace components as necessary. Make sure engine-to-body ground straps are
secure.
Control Circuit
1. Connect the voltmeter leads: RED to the battery positive (+) terminal, BLACK to
terminal "50" of the starting motor.
2. On vehicles with automatic transmission, place the lever in Park or Neutral. On

vehicles with manual transmission, depress the clutch.
(NOTE: A jumper wire could be used to bypass either of these switches).
3. Crank the engine and observe the voltmeter. Less than .5 volt is acceptable. If the
current draw was high or cranking speed slow, the starter motor is defective. More
than .5 volt indicates excessive resistance. Isolate the trouble and correct the cause.
4. Check the neutral start switch or clutch switch for excessive voltage drop. Also check
the ignition switch. Adjust or replace a defective switch, as necessary.
5. An alternate method to
checking the voltage drop
across each component is
to leave the voltmeter
connected to the battery (+)
terminal and move the
voltmeter negative lead
back through the circuit
toward the battery. The
point of high resistance is
found between the point
where voltage drop fell
within specs and the point
last checked.

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ASSESSMENT TASKS:
This assessment tasks should be completed when you are confident that you can
install a starter motor and re-check serviceability. Assessment needs to conform to the
rules of evidence. Therefore:
Trainer’s check
Self
Component
check Competent Not yet
competent
(a) Repairing Starting System
Prepared supplies and materials, tools, tester

and equipment
Repaired/replaced starting motor parts
Reassembled unit
Tested and recorded findings for

serviceability
Installed starter motor to vehicle and re-

checked for serviceability

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PERFORMANCE TEST
Learner's Name Date

Competency: Service Starting System Test Attempt
1st 2nd 3rd
Directions: OVERALL EVALUATION

Level
CALL INSTRUCTOR, ask Achieved PERFORMANCE LEVELS
instructor to assess your
performance in the 4 - Can perform this skill without supervision and with
initiative and adaptability to problem situations.
following critical task and
performance criteria below 3 - Can perform this skill satisfactorily without
assistance or supervision.
You will be rated based on 2 - Can perform this skill satisfactorily but requires
the overall evaluation on some assistance and/or supervision.
the right side.
1 - Can perform parts of this skill satisfactorily, but
requires considerable assistance and/or supervision.
Instructor will initial level achieved.
PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a "Yes" Yes No N/A
or "N/A" response.
1. Identifying starter components, types and classification
2. Conducting starter component failure analysis
a. Pull-in test
b. Hold-in test
c. Pinion return test
d. Check pinion clearance
e. No-load test
3. Filling up job order form
4. Role play
5. Preparing tools, area and tester/equipment needed
6. Pulling out starting motor
7. Disassembling a starter motor
8. Performing starter motor inspection/measurement and record
reading
9. Repair/Replace starter motor
10. Reassemble starter motor
11. Test and record findings
12. Install starter motor and re-check serviceability

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Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing
further details to an Assessor.
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DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing
further details to an Assessor.
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Record of Achievement
Servicing Stating System
LO 1: Test Starting System Components and Identify Faults

Performance Criteria:
1.1 Work is completed without causing damage to any workplace property or vehicle.
1.2 Correct information is accessed and interpreted from appropriate manufacturer specifications
1.3 Tests are carried out to determine faults using appropriate tools and techniques.
1.4 Faults are identified and preferred repair action is determined.
Comments:
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Learner has satisfied the above performance criteria.

Learner signature:.........................................................................
Trainer signature:..........................................................................
Date:..............................................................................................

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LO 2: Disassemble Starter Motor
2.1 Different types of starter motor are disassembled correctly.
2.2 Disassembled components were tested in accordance with the manufacturer's specifications.
2.2 Inspection of different types of motor were carried out using the manufacturer's specification,
service and repair manual.
2.3 Different types of starter motors were assembled properly.
Comments:
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Date:..............................................................................................

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LO 3: Repair, Replace and Assemble Starter Component Parts
3.1 Different types of starter motors are repaired/replaced
3.2 Inspection of different types of motor were carried out using the manufacturer's specification,
service and repair manual.
3.3 Different types of starter motors were assembled properly.
Comments:
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SOLUTION TO
ACTIVITY #3b
ASSESSMENT, LO1
Page 35
For Resistance
RT = R1 + R 2 + R 3
= 2 + 4 + 6
= 12
For Current
E
I =
R
12V
=
12
= 1A (ampere)
For Voltage
E1 = I x R1
= 1A x 2
= 2V
E2 = I x R2
= 1A x 4
= 4V
E3 = I x R3
= 1A x 6
= 6V
ET = E1 + E 2 + E 3
= 24V + 4V + 6V
= 12V

ALT723307
Answers to Activity #3b, LO2: Page 53
1. Magnetic switch set bolt 9. Seal

2. Magnetic switch assembly 10. Bolt
3. Bearing cover 11. Drive housing
4. Lock plate, O ring & rubber 12. Drive lever
5. Bolt 13. Armature
6. Commutator end frame 14. Snap ring & stop collar
7. Brush holder 15. Clutch with pinion gear
8. Yoke

ALT723307
Terms and Definitions
Accumulator - A gas filled pressure chamber Electrical load - The working device of the
that provides hydraulic pressure for ABS circuit.
operation. Electromagnetism - A form of magnetism
A circuit - A generator circuit that uses an that occurs when current flows through
external grounded field circuit. The a conductor.
generator is on the ground side of the field Electromotive force (EMF) - See voltage.
coil. Field current draw test - Diagnostic test
Ammeter - A test meter used to measure that determines if there is a current
current draw. available to the field windings.
Amperes - See current. Floor jack - A portable hydraulic tool used
Analog - A voltage signal that is infinitely to raise and lower a vehicle.
variable or can be changed within a given Fuse - A replaceable circuit protection
range. device that will melt should the current
Battery terminal test - Checks for poor passing through it exceeds its rating.
electrical connections between the battery Fusible link - A wire made of meltable
cables and terminals. Use a voltmeter to material with a special heat-resistant
measure voltage drop across the cables insulation. When there is an overload in
and terminals. the circuit, the link melts and opens the
B circuit - A generator regulator circuit that is circuit.
internally grounded. In the B circuit, the Ground - The common negative
voltage regulator controls the power side connection of the electrical system that
of the filed circuit. is the point of the lowest voltage.
Bench test - A term used to indicate that the Grounded circuit - An electrical defect
unit is to be removed from the vehicle and that allows current to return to ground
tested. before it has reached the intended load
Brushes - Electrically conductive sliding component.
contacts, usually made of copper and Ground side - The portion of the circuit
carbon. that is from the load component to the
Circuit - The path of electron flow consisting negative side of the source.
of the voltage source, conductors, load Growler - Test equipment used to test
component, and return path to the voltage starter armatures for shorts and
source. grounds. It produces a very strong
Commutator - A series of conducting magnetic field that is capable of
segments located around one end of the inducing a current flow and magnetism
armature. in a conductor.
Conductor - A substance that is capable of Hydrometer - A test instrument used to
supporting the flow of electricity through it. check the specific gravity of the
electrolyte to determine the battery's
Continuity - Refers to the circuit being
state of charge.
continuous with no opens.
Insulator - A substance that is not capable
Current - The aggregate flow of electrons
of supporting the flow of electricity.
through a wire. One ampere represents
Jack stands - Support devices used to
the movement of 6.25 billion electrons (or
hold the vehicle off the floor after it has
one coulomb) past one point in a
been raised by the floor jack.
conductor in one second.
Lamp - A device that produces light as a
Current draw test - Diagnostic test used to result of current flow through a filament.
measure the amount of current that the The filament is enclosed within a glass
starter draws when actuated. It envelope and is a type of resistance
determines the electrical and mechanical wire that is generally made from
condition of the starting system. tungsten.

ALT723307
Magnetism - An energy form resulting from Series-parallel circuit - A circuit that have
atoms aligning within certain materials, some loads in series and some in
giving the materials the ability to attract parallel.
other metals. Short - An electrical fault that allows for
Ohm - Unit of measure for resistance. One electrical current to bypass its normal
ohm is the resistance of the conductor path.
such that a constant current of one Solenoid - An electromagnetic device that
ampere in it produces a voltage of one uses movement of a plunger to exert a
volt between its ends. pulling or holding force.
Ohmmeter - A test meter used to measure Splice - The joining of single wire ends or
resistance and continuity in a circuit. the joining of two or more electrical
Ohm's law - Defines the relationship between conductors at a single point.
current, voltage and resistance. State of charge - The condition of a
Open circuit - A term used to indicate that battery's electrolyte and plate materials
current flow is stopped. By opening the at any given time.
circuit, the path for electron flow is broken. Voltage - The difference or potential that
Overload - Excess current flow in a circuit. indicates an excess of electrons at the
Parallel circuit - A circuit that provides two or end of the circuit the farthest from the
more paths for electricity to flow. electromotive force. It is the electrical
pressure that causes electrons to move
Relay - A device that uses low current to
through a circuit. One volt is the
control a high current circuit. Low current
amount of pressure required to move
is used to energize the electromagnetic
one amp of current through one ohm of
coil, while high current is able to pass
resistance.
over the relay contacts.
Voltage drop - A resistance in the circuit
Resistance - Opposition to current flow. that reduces the electrical pressure
Series circuit - A circuit that provides a available after the resistance. The
single path for current flow from the resistance can either be the load
electrical source through the circuit's component, the conductors, any
components, and back to the source. connections, or unwanted resistance.

ALT723307
ACKNOWLEDGEMENT
Copyright TESDA
First Published AUGUST 2003
This draft was prepared at the Self Paced Learning Instrument Development
Workshop conducted at the TESDA Women’s Center, from 11 th to 15th August
2003.
It was based on the competency standard for Automotive Service Technician

developed by the Skill Standard and Certification Office (SSCO), and the
Competency-Based Curriculum Instructional Modules developed by the National
Institute for Technical Vocational Education and Training (NITVET), Technical
Education and Skills Development Authority (TESDA).
Some materials for contextual learning (science, math and communication) were
supplied by Academic Teachers from different TESDA-supervised schools. The
International Consultant for Contextual Learning, Alastair Carnegie edited the
draft for contextual learning.
This learning instrument was developed by the following personnel:
Technology Instructors: Santiago Esquivel, Cesar Ancheta, Rod Dedase;

Academic Teachers: Sonita Camacam, Jovita Pasamic, Llarena Ocampo;
Facilitator: Abel Elpedes
This work was produced with funding provided by TESDA.
REFERENCE AND FURTHER READING
1. Toyota Starting Systems, Toyota Motor Series, U.S.A., Inc.
2. Nippondenso Starter Manual, Nippondenso Service Department, Japan, 1978
3. Today's Technician,

ALT723307

Servicing Starting System

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COMPETENCY BASED LEARNING MATERIAL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

You are required to go through a series of learning activities in order to complete

Recognition of Prior Learning (RPL)

Upon completion of this module you should be able to:

 Test starting system components and identify its faults;

 Disassemble starter motor; and

 Repair/Replace and assemble starter components/parts.

1. Test starting system/components and identify faults:

Code No. Date: Developed Date: Revised Page #

2. Modules on the following:

Code No. Date: Developed Date: Revised Page #

Learning Outcome # 1 : TEST STARTING SYSTEM AND IDENTIFY FAULTS

Learning Activities Special Instructions

1. Identify starting system components,  Read Information Sheet # 1a

 Read Information Sheet # 1b -

 Read Information Sheet # 1c

 Read Information Sheet # 1d.

2. Scale reading of analog/digital  Follow procedures on Operation

Code No. Date: Developed Date: Revised Page #

EQUIPMENT AND MATERIALS:

 Running condition engine

Activity # 1: IDENTIFY STARTING SYSTEM COMPONENTS, TYPES

a. Read Information Sheet 1a, and then answer these questions.

 How does a starting motor operate?

b. Read Information Sheet 1b before answering these questions.

 Do you know how a starting motor operates?

c. Read Information Sheet 1c before answering this question.

 How is each type of starter motor differs from each other?

d. Read Information Sheet 1d before answering these questions.

 What distinct type is commonly used at present?

Code No. Date: Developed Date: Revised Page #

1. Automotive Battery - is a device that converts chemical energy into electric

4. Ignition Switch - a mechanical switch which connect and controls electrical

Code No. Date: Developed Date: Revised Page #

1. CONVENTIONAL STARTER MOTOR

IGNITION SWITCH IN “ST”

 Current flows from the battery through

PINION AND RING GEARS ENGAGED

 When the gears are meshed, the

IGNITION SWITCH IN “ON”

 Current no longer flows to terminal “50,”

Code No. Date: Developed Date: Revised Page #

IGNITION SWITCH IN “ST”

 Current flows from the battery through

PINION AND RING GEARS ENGAGED

 When the gears are meshed, the

IGNITION SWITCH IN “ON”

 Current no longer flows to terminal “50,”

Code No. Date: Developed Date: Revised Page #

1. CONVENTIONAL STARTER MOTOR

CONVENTIONAL STARTER MOTOR

Code No. Date: Developed Date: Revised Page #

Code No. Date: Developed Date: Revised Page #

The planetary type starter uses a

1. Speed Reduction Mechanism

Reduction of the armature shaft's

When the armature shaft turns, the