Checking the brushes
Use a caliper to measure the height of the brushes.
Nominal brush height:
- starter 0.8 kW - 14.0 mm
- starter 1.2 kW - 15.5 mm
- starter 1.4 kW - 15.0 mm
- starter 2.2 kW - 16.5 mm
Minimum allowable brush height:
- starter 0.8 kW - 9.0 mm
- starter 1.2 kW - 11.0 mm
- starter 1.4 kW - 10.0 mm
- starter 2.2 kW - 9.0 mm
If the brush height is less than the minimum allowable value, replace the brushes and correct with sandpaper.
Checking the brush springs
Using a spring balance, measure the tension of the brush springs at the moment they break away from the brush.
Nominal force of brush springs:
- starter 0.8 kW - 13.7-17.7 N
- starter 1.2 kW - 15.0-19.0 N
- starter 1.4 kW - 18-24 N
- starter 2.2 kW - 30 N
Minimum force of brush springs:
- starter 0.8 kW - 9 N
- starter 1.2 kW - 10N
- starter 1.4 kW - 12 N
- starter 2.2 kW - 18 N
The original can be found on this resource (ToyotaMAN)
If the spring force is less than the minimum value, replace the brush springs.
Checking the brush holder
Check the insulation of the brush holder. Use an ohmmeter to check for conductivity between the positive "+" and negative brush holders. If not, replace the brush holder.
