STARTER (for 1.7 kW Type) INSPECTION


  1. INSPECT STARTER ARMATURE ASSEMBLY


    1. Inspect the commutator for an open circuit.


      1. B007UMUE02
        Text in Illustration
        *1 Segment

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

        Standard Resistance
        Tester Connection Connection Specified Condition
        Segment - Segment Always 2.7 to 3.3 Ω

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

    2. Inspect the commutator for a short circuit.


      1. B007TNME02
        Text in Illustration
        *1 Segment
        *2 Coil Core

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

        Standard Resistance
        Tester Connection Connection Specified Condition
        Segment - Coil Core Always 10 kΩ or higher

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

    3. 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.

    4. B007V1M

      Check the commutator circle runout.


      1. Place the commutator on V-blocks.

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

        Standard circle runout
        0.02 mm (0.000787 in.)
        Maximum circle runout
        0.04 mm (0.00157 in.)

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

    5. B007QU4

      Using a vernier caliper, measure the commutator diameter.

      Standard commutator diameter
      32.2 mm (1.27 in.)
      Minimum commutator diameter
      31.1 mm (1.22 in.)

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

    6. B007ON5

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

      Standard undercut depth
      0.9 mm (0.0354 in.)
      Minimum undercut depth
      0.4 mm (0.0157 in.)

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

  2. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. B007SP9

      Using a vernier caliper, measure the brush length.

      Standard brush length
      11.3 mm (0.445 in.)
      Minimum brush length
      7.5 mm (0.295 in.)

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

    2. B007SR2E01

      Check the brush holder.


      1. Measure the resistance between the brushes.

        Standard Resistance
        Tester Connection Specified Condition
        A - B 10 kΩ or higher
        A - C 10 kΩ or higher
        A - D Below 1 Ω
        B - C Below 1 Ω
        B - D 10 kΩ or higher
        C - D 10 kΩ or higher

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

  3. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. Check the starter clutch pinion gear.


      1. B007SKYE02
        Text in Illustration
        *a Free
        *b Lock

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

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

  4. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. B007OCEE02
        Text in Illustration
        *1 Switch Body
        *2 Spring
        *3 Plunger

        Install the plunger and spring onto the switch body.

      2. B007VOI

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

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

    2. Inspect the pull-in coil.


      1. B007VL9E03
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

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

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

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

    3. Inspect the holding coil.


      1. B007TLAE03
        Text in Illustration
        *1 Terminal 50
        *2 Switch Body

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

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

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