Subaru Legacy III (2000-2003 year). Manual - part 94

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STARTING/CHARGING SYSTEMS

STARTER

5) Install brush holder in alignment with Yoke’s
groove.

6) Install rear bracket.
7) When installing switch assembly, catch plunger
protrusion to lever edge.
8) Install connector to switch assembly terminal M.
9) After assembling parts correctly, make sure
starter operates properly.

E: INSPECTION

1. ARMATURE

1) Check commutator for any sign of burns of rough
surfaces or stepped wear. If wear is of a minor na-
ture, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it ex-
ceeds the limit.

Commutator run-out:

Standard

0.05 mm (0.0020 in)

Service limit

Less than 0.10 mm (0.0039 in)

3) Depth of segment mold
Check the depth of segment mold.

Depth of segment mold:

0.5 mm (0.020 in)

4) Armature short-circuit test
Check the armature for short-circuit by placing it on
growler tester. Hold a iron sheet against the arma-
ture core while slowly rotating armature. A short-
circuited armature will cause the iron sheet to vi-
brate and to be attracted to core. If the iron sheet is
attracted or vibrates, the armature, which is short-
circuited, must be replaced or repaired.

(A) Dial gauge

(B) V-block

SC-00159

SC-00021

( A )

( B )

(A) Depth of mold

(B) Segment

(A) Iron sheet

(B) Grower tester

( C )

( B )

( A )

SC-00022

SC-00023

( A )

( B )

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STARTING/CHARGING SYSTEMS

STARTER

5) Armature ground test
Using a circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is continuity, the ar-
mature is grounded.
Replace the armature if it is grounded.

2. YOKE

Make sure pole is set in position.

3. OVERRUNNING CLUTCH

Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.

CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.

4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the brush length and replace if it exceeds
the service limit.
Replace if abnormal wear or cracks are noticed.

Brush length:

Standard

12.3 mm (0.484 in)

Service limit

7.0 mm (0.276 in)

2) Brush movement
Be sure brush moves smoothly inside brush holder.
3) Brush spring force
Measure brush spring force with a spring scale. If it
is less than the service limit, replace brush holder.

Brush spring force:

Standard

21.6 N (2.2 kgf, 4.9 lb) (when new)

Service limit

5.9 N (0.6 kgf, 1.3 lb)

5. SWITCH ASSEMBLY

Be sure there is continuity between terminals S and
M, and between terminal S and ground. Use a cir-
cuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.

Terminal / Specified resistance:

S — M / Less than 1

Ω

S — Ground / Less than 1

Ω

M — B / More than 1 M

Ω

6. SWITCH ASSEMBLY OPERATION

1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.

CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.

(A) Service limit line

(B) Brush

SC-00024

SC-00102

(A)

(B)

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STARTING/CHARGING SYSTEMS

STARTER

2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.

7. PINION GAP

1) Measure pinion gap while the pinion is pulled out
as shown in the figure.

Pinion gap:

0.5 — 2.0 mm (0.020 — 0.079 in)

If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
nal M of switch assembly, and then connect
terminal M to ground terminal (

−

) of battery with a

lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.

8. PERFORMANCE TEST

The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.

Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.

1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading and measure
the starter speed. Compare these values with the
specifications.

No-load test (Standard):

Voltage / Current

11 V / 90 A max.

Rotating speed

AT: 2,400 rpm or more
MT: 2,800 rpm or more

2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.

Load test (Standard):

Voltage / Load

AT: 7.7 V / 16.0 N·m (1.63 kgf-m, 11.8 ft-lb)
MT: 7.5 V / 8.6 N·m (0.88 kgf-m, 6.4 ft-lb)

Current / Speed

AT: 400 A / 740 rpm or more
MT: 300 A / 920 rpm or more

(A) Terminal S

(B) Terminal M

(A) Pinion

(B) Gap

SC-00160

( A )

( B )

SC-00027

( A )

( B )

( C )

(A) Variable resistance

(B) Magnetic switch

SC-00077

(A)

(B)

(C)

12V

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STARTING/CHARGING SYSTEMS

STARTER

3) Lock test
With starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.

Lock test (Standard):

Voltage / Current

AT: 3.5 V / 940 A or less
MT: 4 V / 650 A or less

Torque

AT: 28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or more
MT: 14.7 N·m (1.50 kgf-m, 10.8 ft-lb) or
more

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