Servicing Starting System

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
OK NOT OK IF NOT OK, WHY?

3. Perform return test on solenoid switch
OK NOT OK IF NOT OK, WHY?

4. Check armature shaft to bushing clearance
(Standard: 0.05 mm, Limit: 0.2 mm

OK NOT OK IF NOT OK, WHY?

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5. Check starter drive housing for cracks/damage
OK NOT OK IF NOT OK, WHY?

6. Check overrunning clutch
OK NOT OK IF NOT OK, WHY?

7. Check commutator run-out
Standard: 01.1 mm, Limit: 0.3 mm
OK NOT OK IF NOT OK, WHY?

8. Check armature for ground
OK NOT OK IF NOT OK, WHY?

9. Check armature for short circuit
OK NOT OK IF NOT OK, WHY?

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10. Check armature for open circuit
OK NOT OK IF NOT OK, WHY?

11. Check depth of mica segment
Standard: 0.5 - 0.8 mm, Limit: 0.2 mm
OK NOT OK IF NOT OK, WHY?

12. Check field frame (housing) for cracks/damage
OK NOT OK IF NOT OK, WHY?

13. Check pole shoe/s for looseness
OK NOT OK IF NOT OK, WHY?

14. Check field coil for open circuit
OK NOT OK IF NOT OK, WHY?

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15. Check field coil for grounded circuit
OK NOT OK IF NOT OK, WHY?

16. Measure brush length. Limit: 12 mm
OK NOT OK IF NOT OK, WHY?

17. Check insulated brush holder for grounded
circuit
OK NOT OK IF NOT OK, WHY?

18. Check brush spring/s for cracks/damage
OK NOT OK IF NOT OK, WHY?

19. Check armature thrust clearance
Limit: 088 mm
OK NOT OK IF NOT OK, WHY?

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20. Check pinion gap - 02 -2.5 mm
OK NOT OK IF NOT OK, WHY?

21. Perform starter no-load test
Starter test voltage = 11 volts
Starter current draw = 40 - 60 amperes
OK NOT OK IF NOT OK, WHY?

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LEARNING EXPERIENCES

Learning Outcome # 3 : REPAIR/REPLACE AND ASSEMBLE STARTER

Learning Activities Special Instructions

1. Prepare supplies, materials, tools and
equipment

2. Repair/Replace starter motor • Study the procedure and perform
Activity #2

3. Reassemble starter motor • Study the procedure and perform
Activity #3.
Note: Reassembly will be done using
the previous type of starter
disassembled.

4. Test the starter motor and record • Fill-up the form on page 80. Have it
findings signed by your facilitator/instructor.

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.

EQUIPMENT AND MATERIALS:

• Tool box
• Jack
• Safety stands
• Creeper
• Starter repair kit
• Multimeter
• Sandpaper #400
• Safety glasses

LEARNING ACTIVITIES:

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:
City Technician Name:
Fax/Cell/Tel no.:
Vehicle Identification Supervisor’s Name:
Number:
Engine Year: Make: Model:
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
SYMPTOM • Melted fusible link • Replace fusible link
Engine cranks too • Loose connections • Clean and tighten connections
slowly to start • Faulty ignition switch • Check switch operation; replace as

Starter keeps running • Faulty magnetic switch, relay, needed

Starter spins, but neutral start or clutch switch • Check and replace as needed
engine will not crank
Starter does not • Mechanical problem in engine • Check engine
engage/disengage • Problem in theft deterrent system • Check service manual for system
properly
POSSIBLE CAUSE tests
ACTION NEEDED
• Weak battery
• Loose or corroded connections • Check battery and charge as
• Faulty starter motor
• Mechanical problems with engine needed

or starter • Clean and tighten connections
• Test starter
• Damaged pinion or ring gear • Check engine and starter; replace
• Faulty plunger in magnetic switch
• Faulty ignition switch or control worn out parts

circuit • Check gears for wear or damage
• Test starter pull-in and hold-in coils
• Binding ignition key • Check switch and circuit
• Faulty over-running clutch
• Damaged or worn pinion gear or components

ring gear • Check key for damage
• Check over-running clutch for
• Faulty magnetic switch
• Damaged or worn pinion gear or proper operation

ring gear • Check gears for damage and wear;

replace as needed

• Bench test starter
• Check gears for damage and wear;

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:

• 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:

Self Component Trainer’s check
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

CALL INSTRUCTOR, ask Level PERFORMANCE LEVELS
instructor to assess your Achieved
performance in the
following critical task and 4 - Can perform this skill without supervision and with
performance criteria below initiative and adaptability to problem situations.

You will be rated based on 3 - Can perform this skill satisfactorily without
the overall evaluation on assistance or supervision.
the right side.
2 - Can perform this skill satisfactorily but requires
some assistance and/or supervision.

1 - Can perform parts of this skill satisfactorily, but
requires considerable assistance and/or supervision.

Instructor will initial level achieved.

PERFORMANCE STANDARDS Yes No N/A
For acceptable achievement, all items should receive a "Yes"
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

1LO : 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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2LO : Disassemble Starter Motor

Performance Criteria:
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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Learner has satisfied the above performance criteria.
Learner signature: ........................................................................
Trainer signature: .........................................................................
Date:.............................................................................................

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3LO : Repair, Replace and Assemble Starter Component Parts

Performance Criteria:
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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Learner has satisfied the above performance criteria.
Learner signature: ........................................................................
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Date:.............................................................................................

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SOLUTION TO
ACTIVITY #3b
ASSESSMENT, LO1

Page 35

For Resistance

RT = R1 + R2 + R3
= 2Ω + 4Ω + 6Ω
= 12Ω

For Current

I = E
R

= 12V
12Ω

= 1A (ampere)

For Voltage

E1 = I x R1
= 1A x 2Ω
= 2V

E2 = I x R2
= 1A x 4Ω
= 4V

E3 = I x R3
= 1A x 6Ω
= 6V

ET = E1 + E2 + E3

= 24V + 4V + 6V
= 12V

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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

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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
coil. Electromotive force (EMF) - See voltage.

Ammeter - A test meter used to measure Field current draw test - Diagnostic test
current draw. that determines if there is a current
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
range. Fuse - A replaceable circuit protection
device that will melt should the current
Battery terminal test - Checks for poor passing through it exceeds its rating.
electrical connections between the battery
cables and terminals. Use a voltmeter to Fusible link - A wire made of meltable
measure voltage drop across the cables material with a special heat-resistant
and terminals. insulation. When there is an overload in
the circuit, the link melts and opens the
B circuit - A generator regulator circuit that is circuit.
internally grounded. In the B circuit, the
voltage regulator controls the power side Ground - The common negative
of the filed circuit. connection of the electrical system that
is the point of the lowest voltage.
Bench test - A term used to indicate that the
unit is to be removed from the vehicle and Grounded circuit - An electrical defect
tested. that allows current to return to ground
before it has reached the intended load
Brushes - Electrically conductive sliding component.
contacts, usually made of copper and
carbon. Ground side - The portion of the circuit
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
component, and return path to the voltage Growler - Test equipment used to test
source. starter armatures for shorts and
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
the movement of 6.25 billion electrons (or Jack stands - Support devices used to
one coulomb) past one point in a hold the vehicle off the floor after it has
conductor in one second. been raised by the floor jack.

Current draw test - Diagnostic test used to Lamp - A device that produces light as a
measure the amount of current that the result of current flow through a filament.
starter draws when actuated. It The filament is enclosed within a glass
determines the electrical and mechanical envelope and is a type of resistance
condition of the starting system. wire that is generally made from
tungsten.

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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
ampere in it produces a voltage of one Solenoid - An electromagnetic device that
volt between its ends. uses movement of a plunger to exert a
pulling or holding force.
Ohmmeter - A test meter used to measure
resistance and continuity in a circuit. Splice - The joining of single wire ends or
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
end of the circuit the farthest from the
Parallel circuit - A circuit that provides two or electromotive force. It is the electrical
more paths for electricity to flow. pressure that causes electrons to move
through a circuit. One volt is the
Relay - A device that uses low current to amount of pressure required to move
control a high current circuit. Low current one amp of current through one ohm of
is used to energize the electromagnetic resistance.
coil, while high current is able to pass
over the relay contacts. Voltage drop - A resistance in the circuit
that reduces the electrical pressure
Resistance - Opposition to current flow. available after the resistance. The
resistance can either be the load
Series circuit - A circuit that provides a component, the conductors, any
single path for current flow from the connections, or unwanted resistance.
electrical source through the circuit's
components, and back to the source.

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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 11th 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,

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