STARTER(w/ Stop And Start System) INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    A01VGX6

    Note

    The following tests must be performed within 5 seconds to prevent the coil from burning out.

    Tech Tips

    When replacing the starter assembly, it is necessary to replace the ST1 relay and ST2 relay.


    1. Perform a pull-in test.


      1. Remove the nut and disconnect the motor lead wire from terminal C.

      2. A01VE4AE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50
        *3 Body

        Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear is extended.

        If the clutch pinion gear does not move, replace the magnet starter switch assembly.

        If the clutch pinion gear does not extend, replace the starter assembly, ST1 relay andST2 relay.

    2. A01VDRME02
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50
      *3 Body

      Perform a holding test.


      1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.

        If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

        If the clutch pinion gear does not extend, replace the starter assembly, ST1 relay andST2 relay.

    3. A01VG4NE02
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50
      *3 Body

      Inspect the clutch pinion gear return.


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

        If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

        If the clutch pinion gear does not extend, replace the starter assembly, ST1 relay andST2 relay.

    4. A01VGX6

      Perform a no-load performance test.


      1. Connect the motor lead wire to terminal C. Make sure that the lead is not grounded.

        Torque:
        10 N*m  { 102 kgf*cm, 7.4 ft.*lbf }

      2. Clamp the starter in a vise.

        Note

        Do not clamp the vise too tightly.

      3. A01VG4XE01
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50
        *3 Body

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

      4. 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 100 A

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

        If the clutch pinion gear does not extend, replace the starter assembly, ST1 relay andST2 relay.

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01VFMS

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

        If necessary, replace the magnet starter switch assembly.

    2. A01VIQ0E02
      Text in Illustration
      *1 Terminal 50
      *2 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. A01VFHIE02
      Text in Illustration
      *1 Switch Body
      *2 Terminal 50

      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 - Switch body Always Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01VLGZE10
      Text in Illustration
      *1 Segment

      Check the commutator.


      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.

    2. A01VKROE14
      Text in Illustration
      *1 Starter Armature Assembly Coil Core
      *2 Segment

      Check the commutator.


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

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

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

    3. Check the commutator surface for dirt and burns.

      If the surface is dirty or burnt, replace the starter armature assembly.

    4. A01VHO2E02
      Text in Illustration
      *1 Armature shaft

      Check the commutator for circle runout.


      1. Place the armature shaft on V-blocks.

      2. 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.

    5. A01VE1BE01
      Text in Illustration
      *a Outer diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (1.142 in.) (at convex part)
      Minimum diameter
      28 mm (1.102 in.) (at convex part)

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

    6. A01VLA1
      Text in Illustration
      *a 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
      0.2 mm (0.00787 in.) (at convex part)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01VFNLE03
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the brush length.

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

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

    2. A01VEVLE01

      Check the brush holder.


      1. 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.

    3. A01VDYXE17
      Text in Illustration
      *1 Brush
      *2 Brush Spring

      Inspect the load of the brush spring.


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

        Standard length
        22.3 to 27.3 N (2.3 to 2.7 kgf)
        Minimum length
        13.8 N (1.4 kgf)

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

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. 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.

    2. A01VJN9E05
      Text in Illustration
      *a Free
      *b Lock

      Check the movement of the clutch pinion gear.


      1. Hold the starter clutch, 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.