STARTER (for 2.0 kW Type) INSPECTION


  1. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Inspect the pull-in coil.


      1. B007QJWE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        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 magnet starter switch assembly.

    2. Inspect the holding coil.


      1. B007PTYE02
        Text in Illustration
        *1 Switch Body
        *2 Terminal 50

        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 magnet starter switch assembly.

  2. INSPECT BRUSH


    1. B007R3KE10
      Text in Illustration
      *1 Length
      *a Brush Holder Side
      *b Starter Yoke Side

      Using a vernier caliper, measure the brush length.

      Standard brush length
      15.0 mm (0.591 in.)
      Minimum brush length
      9.0 mm (0.354 in.)

      If the length is less than the minimum, replace the starter brush holder assembly and starter yoke assembly.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Inspect the insulation.


      1. B007TUDE02

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

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

        If the result is not as specified, repair or replace the starter brush holder assembly.

    2. Check the brush spring load.


      1. B007U28E11
        Text in Illustration
        *1 Brush Spring
        *2 Brush

        Take a pull scale reading as soon as the brush spring separates from the brush.

        Standard spring load
        22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)
        Minimum spring load
        12 N (1 kgf, 2.8 lbf)

        If the spring load is less than the minimum, replace the starter brush holder assembly.

  4. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the field coil for an open circuit.


      1. B007W27E01

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead wire - Brush Always Below 1 Ω

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

      2. B007U8WE03
        Text in Illustration
        *1 Terminal A
        *2 Terminal B

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal A -Terminal B 20°C (68°F) 1.5 to 1.9 Ω

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

  5. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

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

    2. Inspect the commutator for an open circuit.


      1. B007V5PE04
        Text in Illustration
        *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. Inspect the commutator for a short circuit.


      1. B007S5VE04
        Text in Illustration
        *1 Segment
        *2 Armature Core

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Armature core Always 10 kΩ or higher

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

    4. Check the commutator circle runout.


      1. B007VOVE01

        Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circle runout.

        Maximum circle runout
        0.05 mm (0.00197 in.)

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

    5. Check the commutator diameter.


      1. B007S3NE01

        Using a vernier caliper, measure the commutator diameter.

        Standard commutator diameter
        35.0 mm (1.38 in.)
        Minimum commutator diameter
        34.0 mm (1.34 in.)

        If the diameter is less than the minimum, replace the starter armature assembly.

    6. B007Q6RE01

      Check the undercut depth.


      1. Using a vernier caliper, measure the undercut depth of the commutator.

        Standard undercut depth
        0.7 mm (0.0276 in.)
        Minimum undercut depth
        0.2 mm (0.00787 in.)

        If the undercut depth is less than the minimum, replace the starter armature assembly.

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. B007T1U

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

      Text in Illustration
      B007USN Free
      B007QIC Lock

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

    2. Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

      If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.