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. If not, the cable may become hot and cause injury.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a pull-in test.


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

      2. A01RED7C01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B005NIZ Moves outward

        Connect a battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the repair service starter kit.

    2. Perform a hold-in test.


      1. A01RAIBC01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B005NIZ Disconnect

        While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

        If the clutch pinion gear returns inward, replace the repair service starter kit.

    3. Perform a return test.


      1. A01R9Q8C01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B005NIZ Disconnect
        B005LWS Returns inward

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

        If the clutch pinion gear does not return inward, replace the repair service starter kit.

    4. Perform a no-load performance test.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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

        Note

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

      3. A01REGYC01
        *a Terminal 50
        *b Terminal 30
        *c Starter Body
        B005NIZ Rotates

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

        Note

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

      4. Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.

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

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A

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

  2. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

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


    1. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

    2. A01RF0LC10
      *a Segment

      Check the commutator for an open circuit.


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

    3. A01RBNHC07
      *a Segment
      *b Starter Armature Core

      Check the commutator for a short circuit.


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

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

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

    4. A01R99OC02
      *a 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 greater than the maximum, replace the starter armature assembly.

  3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01REQHC06
      *a Length

      Check the brush length.


      1. 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. A01R9UGC08
      *a Positive (+) Brush
      *b Negative (-) Brush

      Check the brush insulation.


      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.

  4. INSPECT STARTER CLUTCH

    A01RB8DC06
    *a Lock
    *b Free

    1. Check the clutch pinion gear.


      1. 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 the clutch pinion gear does not operate as specified, replace the starter drive housing assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. A01RDD7

      Check the plunger.


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

        If the plunger does not operate as specified, replace the repair service starter kit.

    2. A01RER6C07
      *a Terminal 50
      *b Terminal C

      Check the pull-in coil for 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 result is not as specified, repair service starter kit.

    3. A01RE47C09
      *a Terminal 50
      *b Magnet Switch Body

      Check the holding coil for 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 -Magnet switch body Always Below 2 Ω

        If the result is not as specified, replace the repair service starter kit.