PROCEDURE
-
Click here
INSPECT STARTER ASSEMBLY
Note:The following tests must be performed within 5 seconds to prevent the coil from burning out.
-
Perform a pull-in test.
-
Remove the nut and disconnect the motor lead wire from terminal C.
-
Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear is extended.
Table 1. Text in Illustration *1 Terminal C *2 Terminal 50 *3 Body If the clutch pinion gear does not move, replace the magnet starter switch assembly.
-
-
Perform a holding test.
-
Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.
Table 2. Text in Illustration *1 Terminal C *2 Terminal 50 *3 Body If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
-
-
Inspect the clutch pinion gear return.
-
Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns.
Table 3. Text in Illustration *1 Terminal C *2 Terminal 50 *3 Body If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
-
-
Perform a no-load performance test.
-
Connect the motor lead wire to terminal C. Make sure that the lead is not grounded.
10 N*m 102 kgf*cm 7.4 ft.*lbf -
Clamp the starter in a vise.
Note:Do not clamp the vise too tightly.
-
Connect the battery and an ammeter to the starter as shown in the illustration.
Table 4. Text in Illustration *1 Terminal 30 *2 Terminal 50 *3 Body -
Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. 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.
-
-
- Click here
INSPECT MAGNET STARTER SWITCH ASSEMBLY
-
Check the plunger.
-
Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the magnet starter switch assembly.
-
-
Check the pull-in coil for an open circuit.
-
Measure the resistance according to the value(s) in the table below.
Table 5. Text in Illustration *1 Terminal 50 *2 Terminal C 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.
-
-
Check the holding coil for an open circuit.
-
Measure the resistance according to the value(s) in the table below.
Table 6. Text in Illustration *1 Switch Body *2 Terminal 50 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.
-
-
- Click here
INSPECT STARTER ARMATURE ASSEMBLY
-
Check the commutator.
-
Measure the resistance according to the value(s) in the table below.
Table 7. Text in Illustration *1 Commutator 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.
-
-
Check the commutator.
-
Measure the resistance according to the value(s) in the table below.
Table 8. Text in Illustration *1 Armature Coil Core *2 Commutator Standard Resistance Tester Connection Condition Specified Condition Commutator - Armature coil core Always 10 kΩ or higher If the result is not as specified, replace the starter armature assembly.
-
-
Check the commutator surface for dirt and burns.
If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.
-
Check the commutator for circle runout.
Table 9. Text in Illustration *1 Armature shaft
-
Place the armature shaft on V-blocks.
-
Using a dial indicator, measure the circle runout.
Standard runout 0.02 mm (0.000787 in.) Maximum runout 0.05 mm (0.00197 in.) If the runout is greater than the maximum, replace the starter armature assembly.
-
-
Using a vernier caliper, measure the commutator diameter.
Standard diameter 29 mm (1.142 in.) Minimum diameter 28 mm (1.102 in.) If the diameter is less than the minimum, replace the armature.
-
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.) Minimum undercut depth 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, adjust it with a hacksaw blade.
-
- Click here
INSPECT STARTER BRUSH HOLDER ASSEMBLY
-
Using a vernier caliper, measure the brush length.
Standard length 14.4 mm (0.567 in.) Minimum length 9.0 mm (0.354 in.) If the brush length is less than the minimum, replace the starter brush holder assembly.
-
Check the brush holder.
-
Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Brush holder A - B Always 10 kΩ or higher Brush holder A - C Always 10 kΩ or higher Brush holder A - D Always Below 1 Ω Brush holder B - C Always Below 1 Ω Brush holder B - D Always 10 kΩ or higher Brush holder C - D Always 10 kΩ or higher If the standard is not met, replace the starter brush holder assembly.
-
-
- Click here
INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
-
Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear and damage.
If damaged, replace the gear or clutch assembly. Also check the planetary gear for wear or damage.
-
Check the movement of the clutch pinion gear.
Table 10. Text in Illustration *a Free *b Lock
-
Hold the starter clutch, 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 cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.
-
-