STARTER 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. Perform a pull-in test.

      1. Remove the nut and disconnect the field coil wire from terminal C.

      2. 

         *1	Terminal C
         *2	Terminal 50

         Connect the battery to the starter magnetic switch 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 starter magnetic switch assembly.

   2. 

      Disconnect

      Perform a holding test.

      1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains out.

         If the clutch pinion gear moves inward, replace the starter magnetic switch assembly.

   3. 

      Disconnect

      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 starter magnetic switch assembly.

   4. 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.

         6.5 N*m

         66 kgf*cm

         58 in.*lbf

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

      3. 

         *1	Terminal 30
         *2	Terminal 50
         *3	Terminal C

         Connect the battery and an ammeter to the starter assembly as shown in the illustration.

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

         Standard Current

         Tester Connection	Condition	Specified Condition
         Battery positive (+) terminal - Terminal 30 - Terminal 50	11.5 V	Below 190 A

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

2. INSPECT STARTER ARMATURE ASSEMBLY

   1. Check the surface of the commutator for dirt and burns.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

   2. Inspect the resistance of the commutator.

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

      1. 

         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 resistance is not as specified, replace the starter armature assembly.

      2. 

         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 resistance is not as specified, replace the starter armature assembly.

   3. Check the surface of the commutator for dirt and burns.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

   4. 

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter

      35.0 mm (1.37 in.)

      Minimum Diameter

      34.0 mm (1.34 in.)

      Tip:

      Be sure to measure the commutator diameter at the ridges.

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

   5. Check the commutator circle runout.

      1. 

         *1	Armature Shaft

         Place the armature shaft on V-blocks.

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

         Maximum runout

         0.05 mm (0.00197 in.)

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

   6. 

      Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

      Standard undercut depth

      0.7 mm (0.0276 in.)

      Minimum undercut depth

      0.2 mm (0.00787 in.)

      Tip:

      Be sure to measure the commutator undercut depth at a cutout.

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

3. INSPECT STARTER YOKE ASSEMBLY

   1. Inspect the resistance of the field coil.

      1. 

         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 resistance is not as specified, replace the starter yoke assembly.

      2. 

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Brush - Starter yoke body	Always	10 kΩ or higher

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

4. INSPECT BRUSH

   1. 

      *1	Length
      *a	Starter Brush Holder Assembly Side
      *b	Starter Yoke Assembly Side

      Using a vernier caliper, measure the brush length.

      Standard Length

      15.0 mm (0.591 in.)

      Minimum Length

      9.0 mm (0.354 in.)

      Tip:

      Be sure to measure the brush lengths at the protrusions.

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

5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   1. Inspect the insulation.

      1. 

         Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

         Standard Resistance

         10 kΩ or higher

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

   2. Inspect the load of the brush spring.

      1. 

         *1	Brush
         *2	Brush Spring

         Take the pull scale reading immediately after the brush spring separates from the brush.

         Standard Spring Installed Load

         21.5 to 27.5 N (2 to 3 kgf, 4.8 to 6.2 lbf)

         Minimum Spring Installed Load

         12.3 N (1 kgf, 2.8 lbf)

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

6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   1. Check the gear teeth of the planetary gear and starter center bearing clutch sub-assembly for wear or damage.

      If any gear of the starter center bearing clutch sub-assembly is damaged, replace the starter center bearing clutch sub-assembly.

   2. 

      *a	Free
      *b	Lock

      Check the movement of the clutch pinion gear.

      1. Rotate the clutch pinion gear clockwise, and check that it turns freely.

      2. Try to rotate the clutch pinion gear counterclockwise, and check that it locks.

         If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY

   1. 

      Check the plunger.

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

         If necessary, replace the starter magnetic switch assembly.

   2. 

      *1	Terminal 50
      *2	Terminal C

      Check if the pull-in coil has an open circuit.

      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 resistance is not as specified, replace the starter magnetic switch assembly.

   3. Check if the holding coil has an open circuit.

      1. 

         *1	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 resistance is not as specified, replace the starter magnetic switch assembly.