Lexus ES300 (1997 year). Service manual — part 545

P10588

Ohmmeter

Continuity

P10589

Ohmmeter

No Continuity

Z10079

Brush Holder Side

Field Frame Side

Length

Length

ST0019

ST–8

–

STARTING

STARTER

992

1997 LEXUS ES300 (RM511U)

7.

INSPECT FIELD COIL FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.

8.

INSPECT FIELD COIL FOR GROUND

Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.

9.

INSPECT BRUSH LENGTH

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.

10.

INSPECT BRUSH SPRING LOAD

Take the pull scale reading the instant the brush spring sepa-
rates 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.

P13481

Ohmmeter

No Continuity

P02612

Lock

Free

P00231

P00649

P02321

–

STARTING

STARTER

ST–9

993

1997 LEXUS ES300 (RM511U)

11.

INSPECT BRUSH HOLDER INSULATION

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.
12.

INSPECT GEAR TEETH

Check the gear teeth on the pinion gear, idler gear and 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.
13.

INSPECT CLUTCH PINION GEAR

Hold the starter clutch and rotate the pinion gear counterclock-
wise, and check that it turns freely. Try to rotate the pinion gear
clockwise and check that it locks.
If necessary, replace the clutch assembly.

14.

IF NECESSARY, REPLACE CLUTCH ASSEMBLY

(a)

Disassembe the starter housing and clutch assembly.
(1)

Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.

(2)

Push down the pinion gear.

(3)

Using a plastic–faced hammer, tap down the stop
collar.

(4)

Using a screwdriver, pry out the snap ring.

B01227

Stop Collar

Pinion Gear

Compression
Spring

B01228

P00241

Starter Housing

Starter Clutch

Compression
Spring

Clutch Shaft

P00241

Starter Housing

Starter Clutch

Compression
Spring

Clutch Shaft

P00244

ST–10

–

STARTING

STARTER

994

1997 LEXUS ES300 (RM511U)

(5)

Remove these parts:

Stop collar

Pinion gear

Compression spring

(6)

Push down the starter housing, and remove the
spring retainer.

(7)

Disassemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft

(b)

Assemble the starter housing and clutch assembly.
(1)

Assemble these parts:

Starter housing

Starter clutch

Compression spring

Clutch shaft

(2)

Mount a brass bar in a vise, install the starter hous-
ing and clutch assembly to the brass bar.

P00240

Spring
Retainer

Compression

Pinion

Stop
Collar

Gear

Spring

P00230

P00233

P00648

A13163

–

STARTING

STARTER

ST–11

995

1997 LEXUS ES300 (RM511U)

(3)

Push down the starter housing, and install these
parts:

Spring retainer

Compression spring

Pinion gear

Stop collar

(4)

Push down the pinion gear.

(5)

Using snap ring pliers, install a new snap ring.

(6)

Using pliers, compress the snap ring.

(7)

Check that the snap ring fits correctly.

(8)

Remove the starter housing and clutch assembly
from the brass bar.

(9)

Using a plastic–faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.

15.

INSPECT REAR BEARING

Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.