STARTER(for Transaxle M/T with Stop and Start System) 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 became hot and cause injury.

    Note

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


    1. A004A36

      Remove the nut to disconnect the lead wire from the terminal C.

    2. A0048E8C01
      *a Starter Body
      *b Terminal C
      *c Terminal 50
      *d Battery

      Perform a pull-in test.


      1. Connect the 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.

    3. A00489KC01
      *a Starter Body
      *b Terminal C
      *c Terminal 50
      *d Battery

      Perform a holding test.


      1. Check that the pinion gear does not return inward after the lead is disconnected from the terminal C.

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

    4. A0048JSC01
      *a Starter Body
      *b Terminal C
      *c Terminal 50
      *d Battery

      Check return operation.


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

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

    5. A004A36

      Connect the lead wire to terminal C with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 89 in.*lbf }

    6. Perform a no-load performance test.


      1. Clamp the starter assembly in a vise between aluminum plates.

        Note

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

      2. A004AIDC07
        *a Starter Body
        *b Terminal 50
        *c Terminal 30
        *d Ammeter
        *e Battery

        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 pinion gear operates.

      3. Check that the starter operates smoothly and steadily with the pinion gear 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 100 A or less

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A004BDBC04
      *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.

    2. A004A2QC04
      *a Segment
      *b Starter Armature Coil 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 coil core Always 10 kΩ or higher

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

    3. Check the commutator appearance.

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

    4. A004AMQ

      Check the commutator for runout.


      1. Place the commutator 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. A0047V5C09
      *a Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (1.1417 in.) (at convex part)
      Minimum diameter
      28 mm (1.1024 in.) (at convex part)

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

    6. A0048JFC08
      *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
      0.2 mm (0.00787 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. A0049ZTC09
      *a Length

      Check the brush length.


      1. Using a vernier caliper, measure the brush length.

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

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

    2. A00474LE08

      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. A00490R

        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, 3.1 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. A0046RTC13
      *a Free
      *b Lock

      Check the clutch pinion gear.


      1. While holding the starter center bearing clutch sub-assembly, 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. A004B2L

      Check the plunger.


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

        Note


        • To avoid damaging the inside of the magnet switch, do not release the plunger quickly.

        • Do not drop the plunger.

        If necessary, replace the magnet starter switch assembly.

    2. Check the pull-in coil for an open circuit.


      1. A004BHJC17
        *a Terminal 50
        *b Terminal C

        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. Check the holding coil for an open circuit.


      1. A0047T8C16
        *a Terminal 50
        *b Magnet Starter Switch Assembly Body

        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.