STARTING

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . ST–1

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST–2
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . ST–20
 ST–1
STARTING – STARTING SYSTEM

STARTING SYSTEM
ST098–01

ON–VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:
S Connector connection
S Accessory installation, e.g.: theft deterrent system

LEXUS RX300 (RM785E)

ST–2
STARTING – STARTER

STARTER
ST099–02

COMPONENTS

Air Flow Meter Connector

Air Cleaner Cap

Hold–Down Clamp
EVAP Hose

Air Filter

5.0 (50, 44 in.·lbf)

Battery

Air Cleaner Case

Battery Tray

Starter
37 (380, 27)

Starter Wire

Starter Connector
N·m (kgf·cm, ft·lbf) : Specified torque
B12306

LEXUS RX300 (RM785E)

 ST–3
STARTING – STARTER

z Snap Ring
Starter Housing
Stop Collar
Pinion Gear
Compression Spring
Spring Retainer
Starter Clutch

Compression Spring
Starter Housing and
Clutch Assembly Clutch Shaft
Idler Gear
Bearing

Steel Ball
Return
Spring
z Front Bearing Magnetic Switch
Assembly

Armature

z Rear Bearing

z O–Ring
Field Frame
(Field Coil) z O–Ring

Brush Holder

End Cover
z Dust Protector

z Non–reusable part B01154

LEXUS RX300 (RM785E)

ST–4
STARTING – STARTER

Magnetic Switch Assembly

Terminal Insulator
Terminal Nut Contact Plate
17 (173, 13)
z Terminal C Kit part
Terminal
Bolt
Wave Washer
Terminal Insulator
O–Ring

Plunger
z Gasket
End Cover

O–Ring

Terminal Bolt Packing

Terminal Insulator
Wave Washer
Terminal Nut
z Terminal 30 Kit Part 17 (173, 13)
Contact Plate
Terminal Insulator

N·m (kgf·cm, ft·lbf) : Specified torque

z Non–reusable part B11377

LEXUS RX300 (RM785E)

 ST–5
STARTING – STARTER
ST09A–02

REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE AIR CLEANER CAP AND AIR CLEANER
CASE
(a) Disconnect the air flow meter connector, wire clamp and
EVAP hose from air cleaner cap.
(b) Remove the air cleaner cap and air filter.
(c) Remove the 3 bolts and air cleaner case.
Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)

3. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
(c) Remove the 2 bolts and starter.
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)

B04564

LEXUS RX300 (RM785E)

ST–6
STARTING – STARTER
ST09B–02

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)
B01156

Protrusion Identation (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.
B01157

3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY

AND GEAR
(a) Remove the 2 screws.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)

B01158

(b) Remove these parts from the magnetic switch:

(1) (1) Remove the starter housing and clutch assembly.
(4)
(2) Remove the return spring.
(3)
(3) Remove the idler gear.
(4) Remove the bearing.

(2) B01160

4. REMOVE STEEL BALL

Using a magnetic finger, remove the steel ball from the clutch
shaft hole.

B01159

LEXUS RX300 (RM785E)

 ST–7
STARTING – STARTER

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) 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.

B01161

(c) 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

P13528

LEXUS RX300 (RM785E)

ST–8
STARTING – STARTER
ST09C–02

Ohmmeter INSPECTION
1. INSPECT ARMATURE COIL
Continuity
(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.

P10584

Ohmmeter (b) Check the commutator for ground.

Using an ohmmeter, check that there is no continuity be-
No Continuity tween the commutator and armature coil core.
If there is 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 lathe.
P10585

(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.

P10586

(c) Using vernier calipers, measure the commutator diame-

ter.
Standard diameter:
30.0 mm (1.181 in.)
Minimum diameter:
29.0 mm (1.142 in.)
If the diameter is less than minimum, replace the armature.

P10587

(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.
ST0040

LEXUS RX300 (RM785E)

 ST–9
STARTING – STARTER

3. INSPECT FIELD COIL

Ohmmeter (a) Check the field coil for open circuit.
Continuity 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.

P10588

(b) Check the field coil for ground.

Ohmmeter
Using an ohmmeter, check that there is no continuity be-
No Continuity tween the field coil end and field frame.
If there is continuity, repair or replace the field frame.

P10589

Brush Holder Side 4. INSPECT BRUSHES

Using vernier calipers, measure the brush length.
Standard length:
15.5 mm (0.610 in.)
Minimum length:
8.5 mm (0.335 in.)
If the length is less than minimum, replace the brush holder and
field frame.
Length
Field Flame Side

Length
Z10079

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
ST0019 springs.

LEXUS RX300 (RM785E)

ST–10
STARTING – STARTER

Ohmmeter 6. INSPECT BRUSH HOLDER

No Continuity
Check the brush holder insulation.
Using an ohmmeter, check that there is no continuity be-
tween 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, idler gear and
clutch assembly for wear or damage.
P13481 If damaged, replace the gear or clutch assembly.
If damaged, also check the ring gear of the flywheel/drive plate
for wear or damage.

(b) Check the clutch pinion gear.

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

B01162

8. INSPECT MAGNETIC SWITCH

Ohmmeter (a) Check the pull–in coil for open circuit.
Terminal C 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.

Continuity
Terminal 50 B01163

(b) Check the hold–in coil for open circuit.

Ohmmeter 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 while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
Continuity (See page ST–11)
Terminal 50 B01164

LEXUS RX300 (RM785E)

 ST–11
STARTING – STARTER
ST09D–02

REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
(a) Disassemble the starter housing and the clutch assembly.
(1) Mount a brass bar in a vise, and install the starter
housing and clutch assembly to the brass bar.

B01224

(2) Push down the pinion gear.

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

B01225

(4) Using a screwdriver, pry out the snap ring.

B01226

Stop Collar (5) Remove the stop collar.

(6) Remove the pinion gear.
Pinion Gear
(7) Remove the compression spring.
Compression
Spring

B01227

(8) Push down the starter housing, and remove the

spring retainer.
(9) Disassemble the starter housing.
(10) Disassemble the starter clutch.
(11) Disassemble the compression spring.
(12) Disassemble the clutch shaft.

B01228

LEXUS RX300 (RM785E)

ST–12
STARTING – STARTER

Starter Housing Compression (b) Assemble the starter housing and the clutch assembly
Spring (1) Assemble the starter housing.
(2) Assemble the starter clutch.
(3) Assemble the compression spring.
(4) Assemble the clutch shaft.
Clutch
Shaft
Starter
Clutch
B01229

(5) Mount a brass bar in a vise, install the starter hous-

ing and clutch assembly to the brass bar.

B01230

(6) Push down the starter housing, and install the

Stop
spring retainer, compression spring, pinion gear
Collar
and stop collar.
Pinion
Gear

Compression
Spring Spring
Retainer
B01231 B01670

(7) Push down the pinion gear.

(8) Using snap ring pliers, install a new snap ring.

B01232

(9) Using pliers, compress the snap ring.

(10) Check that the snap ring fits correctly.

B01233

LEXUS RX300 (RM785E)

 ST–13
STARTING – STARTER

(11) Remove the starter housing and clutch assembly

from the brass bar.
(12) Using a plastic–faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.

B01165

2. REPLACE FRONT BEARING

SST (a) Using SST, remove the bearing.
SST 09286–46011

P10595

Upward (b) Using SST and a press, press in a new bearing.

SST NOTICE:
Be careful of the bearing installation direction.
SST 09820–00030

Downward P10596

3. REPLACE REAR BEARING

SST
(a) Using SST, remove the bearing.
SST 09286–46011

P10593

(b) Using a press, press in a new bearing.

P10594

LEXUS RX300 (RM785E)

ST–14
STARTING – STARTER

4. REPLACE MAGNETIC SWITCH TERMINAL KIT

PARTS
(a) Remove the 3 bolts, end cover, gasket and the plunger.

B01234

(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.

B01235

(c) Remove the terminal kit parts.

(1) Using SST, loosen the terminal nuts.
SST 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:
B01236 Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O–ring, terminal bolt,
contact plate, terminal insulator (inside) and insula-
tion paper.

(3) (d) Temporarily install these new terminal 30 kit parts:

(4)
Inside Long (1) Install the new terminal insulator (inside).
(5)
(2) Install the new contact plate.
(2)
(1) (3) Install the new terminal bolt.
Short (4) Install the new O–ring.
(5) Install the new packing and terminal insulator (out-
side).
(6) Install the packing to the terminal insulator, and
(7) B11400 install them.

LEXUS RX300 (RM785E)

 ST–15
STARTING – STARTER

HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Install the new wave washer.
(7) Install the new terminal nut.
NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.

Long (e) Temporarily install these new terminal C kit parts:

(7)(6) (5) (4) Short (1) Install the new terminal insulator (inside).
(2) (3) (2) Install the new contact plate.
(1) (3) Install the new terminal bolt.
(4) Install the new O–ring.
(5) Install the new terminal insulator (outside).
(7) (6) Install the new wave washer.
(7) Install the new terminal nut.
Inside Lead Terminal
B01238 NOTICE:
Be careful to install the terminal insulators
(inside) and wave washers in the correct direction.
(f) Temporarily tighten the terminal nuts.

(g) Tighten terminal nuts.

Wooden Block
(1) Put a wooden block on the contact plate and press
40 mm 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.)
37 mm 20 mm Press force:
Contact Plate 981 N (100 kgf, 221 lbf)
NOTICE:
B01239 S Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.
Gauge pressure:
100 kgf
(kgf/cm2) = Ram diameter (cm) 2
x 3.14 (π)
2
221 lbf
2
(psi) = Ram diameter (in.)
x 3.14 (π)
2
(kPa) = (kgf/cm2) x 98.1

(kPa) = (psi) x 6.9

LEXUS RX300 (RM785E)
ST–16
STARTING – STARTER

S 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
SST
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.

B01240

(h) Clean the contact surfaces of the remaining contact plate

and plunger with a dry shop rag.
(i) Reinstall the plunger, new gasket and end cover with the
3 bolts.
Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf)

B01241

LEXUS RX300 (RM785E)

 ST–17
STARTING – STARTER
ST09E–01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST–6).
HINT:
Use high–temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the
starter.

LEXUS RX300 (RM785E)

ST–18
STARTING – STARTER
ST09F–01

TEST
Terminal C NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL–IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Terminal 50 Battery Check that the clutch pinion gear moves outward.
B01242

Disconnect 2. DO HOLD–IN TEST

Terminal C With battery connected as above with the clutch pinion gear
out, disconnect the negative (–) lead from terminal C. Check
that the pinion gear remains out.

Battery
B01243

3. INSPECT CLUTCH PINION GEAR RETURN

(a) Disconnect the negative (–) lead from the switch body.
(b) Check that the clutch pinion gear returns inward.

Disconnect

Battery
B01244

4. DO NO–LOAD PERFORMANCE TEST

(a) Connect the battery and ammeter to the starter as shown.
Terminal 30 (b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
Battery
shows the specified current.
Specified current:
90 A or less at 11.5 V
Terminal 50 Ammeter
B01245

LEXUS RX300 (RM785E)

 ST–19
STARTING – STARTER
ST09G–01

INSTALLATION
Installation is in the reverse order of removal (See page ST–5).

LEXUS RX300 (RM785E)

ST–20
STARTING – STARTER RELAY

STARTER RELAY ST09H–01

INSPECTION
Starter 1. REMOVE RELAY BOX COVER
Relay 2. REMOVE STARTER RELAY (Marking: ST)

B04565

3. INSPECT STARTER RELAY

Ohmmeter (a) Inspect the relay continuity.
No 1 Continuity
Continuity (1) Using an ohmmeter, check that there is continuity
5 between terminals 1 and 2.
Ohmmeter
If there is no continuity, replace the relay.
3 (2) Check that there is no continuity between terminals
2 3 and 5.
If there is continuity, replace the relay.
P07170

(b) Inspect the relay operation.

Ohmmeter
(1) Apply battery positive voltage across terminals 1
1
Continuity and 2.
5 (2) Using an ohmmeter, check that there is continuity
3 between terminals 3 and 5.
If there is no continuity, replace the relay.
2 4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER
Battery P07171

LEXUS RX300 (RM785E)