STARTER(except Cold Area Specification Vehicles) INSPECTION

PROCEDURE

1. INSPECT STARTER ASSEMBLY

   Note

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

   
   

   1. Perform a pull-in test.

      
      
      1. 

         *1	Terminal 50
         *2	Starter Body

         Connect the battery to the magnet starter switch assembly 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.

   2. 

      *1	Terminal 50
      *2	Starter Body

      Inspect the clutch pinion gear return.

      
      

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

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

   3. Perform a no-load performance test.

      
      

      1. Clamp the starter in a vise.

         Note

         Do not clamp the vise too tightly.

      2. 

         *1	Terminal 50
         *2	Terminal 30
         *3	Starter Body

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

      3. 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.

2. INSPECT STARTER ARMATURE ASSEMBLY

   
   

   1. Check the commutator for an open circuit.

      
      
      1. 

         *1

         Segment

         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. Check the commutator for a short to ground.

      
      
      1. 

         *1	Segment
         *2	Starter Armature Coil Core

         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 surface for dirt and burns.

      If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

   4. Check the commutator for circle runout.

      
      

      1. 

         Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circle runout.

         Maximum runout
         0.05 mm (0.00197 in.)

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

   5. 

      *a

      Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      25.0 mm (0.9843 in.)

      Minimum diameter
      24.0 mm (0.9449 in.)

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

   6. 

      *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.)

      Minimum undercut depth
      0.2 mm (0.0079 in.)

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

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   
   

   1. 

      Using a vernier caliper, measure the brush length.

      Standard length
      11.6 mm (0.4567 in.)

      Minimum length
      7.6 mm (0.2992 in.)

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

4. INSPECT STARTER CLUTCH SUB-ASSEMBLY

   
   
   1. 

      *a	Free
      *b	Lock

      Hold the starter clutch sub-assembly, rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

      If necessary, replace the starter clutch sub-assembly.

5. INSPECT MAGNET STARTER SWITCH ASSEMBLY

   
   

   1. Check the plunger.

      
      
      1. 

         *1

         Plunger

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

         If necessary, replace the magnet starter switch assembly.

   2. Check the holding coil for an open circuit.

      
      
      1. 

         *1	Terminal 50
         *2	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.