Starter Assembly (Fa20): Inspection

Inspect Starter Assembly

WARNING: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.

CAUTION: The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.

Mount the starter in a vise between aluminum plates.
Perform a pull-in test.
1. Remove the nut, and then disconnect the lead wire from terminal M.
2. Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear extends.
  
  Fig 1: Performing Pull-In Test
  Courtesy of SUBARU OF AMERICA, INC.
  
  If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
Perform a holding test.
1. Disconnect the negative (-) terminal lead from terminal M while the conditions specified in the pull-in test above are maintained. Check that the pinion gear remains out.
  
  Fig 2: Performing Holding Test
  Courtesy of SUBARU OF AMERICA, INC.
  
  If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
Inspect the clutch pinion gear return.
1. Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward.
  
  Fig 3: Inspecting Clutch Pinion Gear Return
  Courtesy of SUBARU OF AMERICA, INC.
  
  If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Perform an operation test without load.

Connect the lead wire to terminal C with the nut.
Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
Connect the battery and an ammeter to the starter as shown in the illustration.

Fig 4: Performing Operation Test Without Load
Courtesy of SUBARU OF AMERICA, INC.

Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current.

Standard Current

STANDARD CURRENT SPECIFICATION

Tester Connection	Condition	Specified Condition
Battery positive terminal - Terminal B - Terminal M	11.5 V	Below 90 A

If the result is not as specified, inspect the starter assembly.

NOTE: Inspect the starter armature assembly, starter commutator end frame assembly and magnet starter switch assembly. If there is a malfunction, replace the part and perform again this test.

Inspect Starter Armature Assembly (For Manual Transmission)
1. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.
2. Check for runout on the commutator. If excessive, replace the armature.
  Standard runout: 0.05 mm (0.002 in.)
  
  Maximum runout: 0.10 mm (0.004 in.)
  
  Fig 5: Checking Commutator Runout
  Courtesy of SUBARU OF AMERICA, INC.
3. Check the depth of the segment mold. If it is not within the standard, replace the armature.
  Standard depth: 0.05 mm (0.002 in.)
  
  Fig 6: Identifying Segment Mold Depth
  Courtesy of SUBARU OF AMERICA, INC.
4. Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature.
  
  Fig 7: Checking Armature For Short Circuits
  Courtesy of SUBARU OF AMERICA, INC.
5. Touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is continuity, replace the armature.

Inspect Starter Armature Assembly (For Automatic Transmission)

Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

Fig 8: Inspecting Starter Armature Assembly (Automatic Transmission)
Courtesy of SUBARU OF AMERICA, INC.

Inspect the commutator for an open circuit.

Measure the resistance according to the value(s) in the table below.

Fig 9: Inspecting Commutator For Open Circuit

Courtesy of SUBARU OF AMERICA, INC.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Segment - Segment	Always	Below 1 Ω

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

Inspect the commutator for short circuits.

Measure the resistance according to the value(s) in the table below.

Fig 10: Inspecting Commutator For Short Circuits

Courtesy of SUBARU OF AMERICA, INC.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Segment - Coil core	Always	10 kΩ or higher

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

Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.
Check for runout on the commutator. If excessive, replace the armature.
Standard runout: 0.02 mm (0.0008 in.)

Maximum runout: 0.05 mm (0.002 in.)

Fig 11: Checking Commutator Runout
Courtesy of SUBARU OF AMERICA, INC.

If the result is not as specified, replace the starter armature assembly.
Using vernier caliper, measure the commutator diameter.

Fig 12: Measuring Commutator Diameter Using Vernier Caliper
Courtesy of SUBARU OF AMERICA, INC.

Standard diameter: 29 mm (1.1417 in.)

Minimum diameter: 28 mm (1.1024 in.)

If the diameter is less than the minimum, replace the starter armature assembly.
Using vernier caliper, measure the under cut depth of the segment. If it is not within the standard, replace the starter armature assembly.
Standard depth: 0.7 mm (0.0276 in.)

Minimum depth: 0.2 mm (0.0079 in.)

Fig 13: Identifying Segment Under Cut Depth
Courtesy of SUBARU OF AMERICA, INC.

Inspect Starter Yoke Assembly (For Manual Transmission)
1. Make sure that the pole is set at the predetermined position.
Inspect Starter Brush Holder Assembly (For Manual Transmission)
1. Visually check the brush. If there is any abnormal wear or cracks, replace the brush.
2. Measure the length of the brush. If it exceeds the service limits, replace the brush.
  Standard length: 12.3 mm (0.484 in.)
  
  Minimum length: 7.0 mm (0.276 in.)
  
  Fig 14: Inspecting Starter Brush Holder Assembly (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
3. Check that the brush moves smoothly in the brush holder.
4. Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit.
  Standard brush spring force: 15.9 to 19.5 N (1.6 to 2.0 kgf, 3.6 to 4.4 lbf)
  
  Minimum brush spring force: 2.5 N (0.3 kgf, 0.6 lbf)

Inspect Starter Brush Holder Assembly (For Automatic Transmission)

Using a vernier caliper, measure the brush length.

Fig 15: Measuring Brush Length Using Vernier Caliper (Automatic Transmission)
Courtesy of SUBARU OF AMERICA, INC.

Standard length: 14.4 mm (0.5669 in.)

Minimum length: 9.0 mm (0.3543 in.)

If the length is less than the minimum, replace the starter brush holder assembly.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
A - BA - CB - DC - D	Always	10 kΩ or higher
A - DB - C	Always Below	1 Ω

If the result is not as specified, replace the starter brush holder assembly.

Fig 16: Measuring Starter Brush Holder Assembly Resistance

Courtesy of SUBARU OF AMERICA, INC.

Inspect Starter Clutch Sub-Assembly (For Manual Transmission)
1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
  If any of the gears is damaged, replace the starter center bearing clutch sub-assembly.
2. Check the starter clutch pinion gear.
  1. Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
    
    Fig 17: Checking Starter Clutch Pinion Gear
    Courtesy of SUBARU OF AMERICA, INC.
    
    If necessary, replace the starter clutch subassembly.

INSPECT MAGNET STARTER SWITCH ASSEMBLY (for Manual Transmission)

Check that there is continuity between terminals 50 and C, and between terminal 50 and ground. Also, check to be sure there is no continuity between terminal C and 30.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal M - Terminal B	Always	Below 1 Ω
Terminal B - Switch body	Always	Below 1 Ω
Terminal M - Terminal S	Always	1 M Ωor higher

Fig 18: Inspecting Magnet Starter Switch Assembly (Manual Transmission)

Courtesy of SUBARU OF AMERICA, INC.

Using a lead wire, connect the switch assembly terminal 50 to the positive terminal of the battery, and the starter body to the ground terminal of the battery. The pinion should be forced to be pushed out on the shaft.
NOTE: With the pinion forced to be pushed out on the shaft, the starter motor can sometimes rotate because the current flows, through pull-in coil, to motor. This is not a problem.
Disconnect the connector from terminal M. Then, using a lead wire, connect the positive terminal of the battery and terminal M, and ground terminal to starter body. In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver.

Fig 19: Identifying Magnet Starter Switch Assembly Terminals
Courtesy of SUBARU OF AMERICA, INC.

Inspect Magnet Starter Switch Assembly (For Automatic Transmission)

Check the plunger.
1. Push in the plunger and check that it returns quickly to it is original position.
  If necessary, replace the magnet starter switch assembly.
  
  Fig 20: Inspecting Magnet Starter Switch Assembly (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.

Inspect the pull-in coil.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal M - Terminal B	Always	Below 1 Ω

Fig 21: Inspecting Pull-In Coil

Courtesy of SUBARU OF AMERICA, INC.

If the result is not as specified, replace the magnet starter switch assembly.

Inspect the holding coil.

Measure the resistance according to the value(s) in the table below.

Standard Resistance

STANDARD RESISTANCE SPECIFICATION

Tester Connection	Condition	Specified Condition
Terminal B - Switch body	Always	Below 2 Ω

Fig 22: Inspecting Holding Coil

Courtesy of SUBARU OF AMERICA, INC.

If the result is not as specified, replace the magnet starter switch assembly.