TOYOTA SUPRA 1997 Service Repair Manual

ST04E-01
P10564
P10565
P10600
P10566
P10583
(1) (2)(3)(4)
(5)
- STARTINGSTARTER
ST-5
1512 Author
: Date
:
1997 SUPRA (RM502U)
DISASSEMBLY
1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(c) Pull out the field frame together with the armature.
HINT:
Align the protrusion of the field frame with the groove of the
magnetic switch.
(d) Remove the O-ring from the field frame.
HINT:
At the time of installation, please refer to the following items.
Use a new O-ring.
3. REMOVE STARTER HOUSING, CLUTCH
ASSEMBLY AND GEAR
(a) Remove the 2 bolts.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
(b) Remove these parts from the magnetic switch:
(1) Starter housing
(2) Return spring
(3) Idler gear
(4) Bearing
(5) Clutch assembly

ST0948
Magnetic Finger
P10567
P10568
ST-6
- STARTINGSTARTER
1513 Author
: Date
:
1997 SUPRA (RM502U)
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
5. REMOVE BRUSH HOLDER
(a) Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N´m (15 kgf´cm, 13 in.´lbf)
(b) Using a screwdriver, hold the spring back and disconnect
the brush from the brush holder. Disconnect the 4
brushes, and remove the brush holder.
NOTICE:
Check that the positive (+) lead wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME

ST04F-01
P10584
Ohmmeter
Continuity
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
- STARTINGSTARTER
ST-7
1514 Author
: Date
:
1997 SUPRA (RM502U)
INSPECTION
1. INSPECT ARMATURE COIL
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
(b) Check the commutator for ground.
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is no continuity, replace the armature.
2. INSPECT COMMUTATOR
(a) Check the commutator for the dirty and burnt surfaces.
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a table.
(b) Check for the commutator circle runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
(c) Using a vernier caliper, measure the commutator diame-
ter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum diameter: 29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.
(d) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

P10588
Ohmmeter
Continuity
P10589
Ohmmeter
No Continuity
Z07019
Brush Holder Side
Field Frame Side
Length
Length
ST0019
ST-8
- STARTINGSTARTER
1515 Author
: Date
:
1997 SUPRA (RM502U)
3. INSPECT FIELD COIL
(a) Check the field coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
(b) Check the field coil for ground.
Using an ohmmeter, check that there is no continuity be-
tween the field coil end and field frame.
If there is continuity, replace the field frame.
4. INSPECT BRUSHES
Using a vernier caliper, measure the brush length.
Standard length: 15.5 mm (0.610 in.)
Minimum length: 10.0 mm (0.394 in.)
If the length is less than minimum, replace the brush holder and
field frame.
5. INSPECT BRUSH SPRINGS
Check the brush spring load. Take the pull scale reading the
instant the brush spring separates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.8 - 2.4 kgf, 3.9 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is less than minimum, replace the brush
springs.

P10592
Ohmmeter
No Continuity
P10821
Free
LOCK
P10597
Continuity
Terminal COhmmeter
Terminal 50
P10598
ContinuityOhmmeter
Terminal 50
- STARTINGSTARTER
ST-9
1516 Author
: Date
:
1997 SUPRA (RM502U)
6. INSPECT BRUSH HOLDER
Check the brush holder insulator. Using an ohmmeter, check
that there is no continuity between the positive (+) and negative
(-) brush holders.
If there is continuity, repair or replace the brush holder.
7. INSPECT CLUTCH AND GEAR
(a) Check the gear teeth on the pinion gear, idle gear and the
clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.
(b) Check the clutch pinion gear.
Rotate the pinion gear counterclockwise, and check that
it turns freely. Try to rotate the pinion gear clockwise and
check that it locks.
If necessary, replace the clutch assembly.
8. INSPECT MAGNETIC SWITCH
(a) Check the pull -in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
(b) Check the hold-in coil for open circuit.
Using an ohmmeter, check that there is continuity be-
tween terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.
9. INSPECT BEARING
Turn the bearing by hand and while apply inward force.
If resistance is felt or bearing sticks, replace the bearing.
(See page ST-10)

ST04G-01
P10595
SST
P10596
Upward
DownwardSST
P10593
SST
P10594
P25784
Clamp ST-10
- STARTINGSTARTER
1517 Author
: Date
:
1997 SUPRA (RM502U)
REPLACEMENT
1. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820-00030
2. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using a press, press in a new rear bearing.
3. REPLACE MAGNETIC SWITCH TERMINAL
KIT PARTS
(a) Remove the 3 bolts, clamp, end cover, gasket and plung-
er.

P25785
Wear
P25786
SST
P25787
Long
Short
(3)
Indentation
Protrusion (4)
(5) (1)
(2)
(8) (7) (6)
P25788
Long
Short
(3) (4) (5)
(1)(2) (7)
(6)
Lead Terminal
- STARTINGSTARTER
ST-1 1
1518 Author
: Date
:
1997 SUPRA (RM502U)
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts.
(1) Using SST, loosen the terminal nuts.
SST 09810-38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O-ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.
(d) Temporarily install these new terminal 30 kit parts:
(1) Insulation paper
(2) Terminal insulator (inside)
(3) Contact plate
(4) Terminal bolt
(5) O-ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
NOTICE:
Be careful to install the terminal insulators in the correct
direction.
(e) Temporarily install these new terminal C kit parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O-ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulators in the correct
direction.

P25789
40 mm
Contact
Plate 20 mm
37 mmWooden
Block
(kgf/cm2) =Ram diameter (cm)
100 kgf
2x 3.14 (p)
2
(psi) =Ram diameter (in.)
221 lbf
2x 3.14 (p)
2
(kPa) = (kgf/cm2) x 98.1
(kPa) = (psi) x 6.9
P25790
SST
P25791
ST-12
- STARTINGSTARTER
1519 Author
: Date
:
1997 SUPRA (RM502U)
(f) Temporarily tighten the terminal nuts.
(g) Tighten the terminal nut
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then
calculate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 13 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the plunger, new gasket, end cover and lead
clamp with the 3 bolts.
Torque: 2.5 N´m (26 kgf´cm, 22 in.´lbf)

ST04I-01
P10952
Terminal 50
Battery Terminal C
P10953
Battery Terminal CDisconnect
P10954
Battery Disconnect
P10955
Terminal 50
Battery Terminal 30
Ammeter ST-14
- STARTINGSTARTER
1521 Author
: Date
:
1997 SUPRA (RM502U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. PERFORM PULL-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the pinion gear moves outward.
2. PERFORM HOLD-IN TEST
While connected as above with the pinion gear out, disconnect
the negative (-) lead from terminal C.
Check that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the starter body.
Check that the pinion gear returns inward.
4. PERFORM NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

P11569
Starter
Relay
ST04K-01
P07170
No
Continuity
5 OhmmeterContinuity
3
2 1
Ohmmeter
P07171
5 Continuity
3
2 1 Ohmmeter
Battery ST-16
- STARTINGSTARTER RELAY
1523 Author
: Date
:
1997 SUPRA (RM502U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY (Marking: ST)
LOCATION: In the engine compartment relay box.
Remove the relay box cover and starter relay.
2. INSPECT STARTER RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
(a) Apply battery positive voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY