STARTER INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    B000W05

    • Do not use a thin cable to perform the inspection.

    • If a thin cable is used, the large electric current passing through the cable could cause it to overheat and catch fire, possibly resulting in injuries

    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. B000Z94

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

      2. B000VTPC05
        *a Starter Body
        *b Terminal 50
        *c Terminal C
        B000XM7 Moves outward

        Connect a battery to the magnet starter 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 magnet starter switch assembly.

    2. B000U0ZC06
      *a Starter Body
      *b Terminal 50
      *c Terminal C
      B000XM7 Disconnect

      Perform a holding test.


      1. 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 magnet starter switch assembly.

    3. B000UXYC05
      *a Starter Body
      *b Terminal 50
      *c Terminal C
      B000XM7 Disconnect
      B000TT4 Returns inward

      Perform a return test.


      1. 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 magnet starter switch assembly.

    4. Perform a no-load performance test.


      1. B000Z94

        Connect the field coil lead wire to the 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. B000WNNC04
        *a Starter Body
        *b Terminal B
        *c Terminal 50
        B000XM7 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 150 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, replace the starter armature assembly.

    2. B000UD2C01
      *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. B000VV1C01
      *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. B000X7PC06
      *a Armature Shaft

      Check the commutator for runout.


      1. Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum Runout
        0.05 mm (0.00197 in.)

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

    5. B000UU4C06
      *a Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter
      29 mm (1.14 in.) (at convex part)
      Minimum Diameter
      28 mm (1.10 in.) (at convex part)

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

    6. B000XW0C01
      *a Undercut depth

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard Undercut Depth
      0.7 mm (0.0276 in.) (at convex part)
      Minimum Undercut Depth
      0.4 mm (0.0157 in.) (at convex part)

      If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush length.


      1. B000Y4SC01
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard Length
        14.4 mm (0.567 in.) (at convex part)
        Minimum Length
        9.0 mm (0.354 in.) (at convex part)

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

    2. B000X5PN22

      Check the brush holder resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 Always 10 kΩ or higher

        A - D

        B - C

        		 Below 1 Ω

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

    3. Check the brush spring load.


      1. B000X06

        Take a pull scale reading the instant the brush spring separates from the brush.

        Standard Spring Load
        22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)
        Minimum Spring Load
        13.8 N (1.41 kgf, 3.10 lbf)

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

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

      If worn or damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

    2. B000TVCC01
      *a Free
      *b Lock

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

      If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. B000WGK

      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 magnet starter switch assembly.

    2. B000WHHC08
      *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, replace the magnet starter switch assembly.

    3. B000UPNC08
      *a Terminal 50
      *b Magnet Starter Switch Assembly Body

      Check the hold-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 - Magnet starter switch assembly body Always Below 2 Ω

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