STARTER(for 1.7 kW Type) INSPECTION

PROCEDURE

1. INSPECT STARTER ASSEMBLY

   CAUTION:

   As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.

   Note:

   These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

   1. Mount the starter assembly in a vise between aluminum plates.

      Note:

      Ensure that the starter assembly is secured firmly in the vise to prevent it from falling out.

   2. Perform a pull-in test.

      1. 

         Remove the nut and disconnect the lead wire from terminal C.

      2. 

         *1	Terminal 50
         *2	Terminal C
         *3	Body
         	Moves Outward

         Connect the battery to the starter assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

         If the clutch pinion gear does not move outward, replace the motor terminal starter kit.

   3. Perform a holding test.

      1. 

         *1	Terminal 50
         *2	Terminal C
         *3	Body
         	Disconnect

         Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

         If the clutch pinion gear moves inward, replace the motor terminal starter kit.

   4. 

      *1	Terminal 50
      *2	Terminal C
      *3	Body
      	Disconnect
      	Returns Inward

      Inspect the clutch pinion gear return.

      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.

         If the clutch pinion gear does not move inward, replace the motor terminal starter kit.

   5. Perform an operation test without load.

      1. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.

         10 N*m

         102 kgf*cm

         7 ft.*lbf

      2. 

         *1	Terminal 50
         *2	Terminal 30

         Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in the illustration.

         Note:

         Do not allow any leads to get caught as the pinion gear operates.

      3. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

         Standard current

         90 A or less at 11.5 V

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

2. INSPECT MOTOR TERMINAL STARTER KIT

   

   1. Check the plunger.

      1. Push in the plunger and check that it returns quickly to its original position.

         If necessary, replace the motor terminal starter kit.

   2. 

      *1	Terminal 50
      *2	Terminal C

      Inspect the resistance of the pull-in coil.

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Terminal C	Always	Below 1 Ω

         If the result is not as specified, replace the motor terminal starter kit.

   3. Inspect the resistance of the holding coil.

      1. 

         *1	Terminal 50
         *2	Switch Body

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Switch body	Always	Below 2 Ω

         If the result is not as specified, replace the motor terminal starter kit.

3. INSPECT STARTER ARMATURE ASSEMBLY

   Tip:

   If there is no continuity between any segments, replace the starter armature assembly.

   1. Check the commutator for contamination and burns on its surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

   2. Check if the commutator has an open circuit.

      1. 

         *1

         Segment

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

         Standard Resistance

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

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

   3. Check if the commutator is grounded.

      1. 

         *1	Segment
         *2	Coil Core

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

         Standard Resistance

         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.

   4. 

      *1

      Length

      Using a vernier caliper, measure the commutator length.

      Standard length

      3.1 mm (0.122 in.)

      Maximum length

      3.8 mm (0.150 in.)

      If the length is more than the maximum, replace the starter armature assembly.

4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

   1. Check the brush length.

      1. 

         *1

         Length

         Using a vernier caliper, measure the brush length.

         Standard length

         9.0 mm (0.354 in.)

         Minimum length

         4.0 mm (0.157 in.)

         If the length is less than the minimum, replace the starter commutator end frame assembly.

   2. Check the resistance.

      1. 

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Positive (+) brush - Negative (-) brush	Always	10 kΩ or higher

         If the result is not as specified, replace the starter commutator end frame assembly.

5. INSPECT STARTER CLUTCH

   1. Check the starter clutch.

      1. 

         *a	Lock
         *b	Free

         Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.

         If necessary, replace the repair service starter kit.