STARTER INSPECTION


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.

    Note

    The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.

    A01CGU7E03
    Text in Illustration
    *1 Terminal M *2 Terminal B
    *3 Terminal C - -

    1. Mount the starter in a vise between aluminum plates.

    2. Perform a pull-in test.


      1. A01CHIE

        Remove the nut and 2 washers and disconnect the lead wire from terminal M.

      2. Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.

        A01CHF5E03
        Text in Illustration
        *1 Terminal M *2 Terminal C
        A01CHW8 Moves Outward - -

    3. Perform a holding test.


      1. Disconnect the negative (-) terminal lead from terminal M with the conditions specified in the pull-in test above being maintained. Check that the pinion gear remains out.

        A01CJ22E03
        Text in Illustration
        *1 Terminal M *2 Terminal C
        A01CHW8 Disconnect - -

    4. Inspect the clutch pinion gear return.


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

        A01CGTIE03
        Text in Illustration
        *1 Terminal M *2 Terminal C
        *a Disconnect *b Returns Inward

    5. Perform an operation test without load.


      1. Connect the lead wire to terminal M with the 2 washers and nut.

        Torque:
        14 N*m  { 138 kgf*cm, 10 ft.*lbf }

      2. Connect the battery and an ammeter to the starter with terminal C disconnected as shown in the illustration.

        CAUTION:

        Do not connect the battery to terminal C in this step.

        A01CI4PE03
        Text in Illustration
        *1 Terminal B *2 Terminal C
        *a Connect - -

      3. Connect the battery to terminal C and check that the starter rotates smoothly and steadily while the pinion gear is out.

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

        Standard Current
        Tester Connection Condition Specified Condition
        Battery - Terminal C Always 180 A or less

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the surface of the commutator for dirt and burns.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

    2. Inspect the commutator for an open circuit.


      1. A01CHPEE02
        Text in Illustration
        *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.

    3. Inspect the commutator for a short circuit.


      1. A01CI3PE02
        Text in Illustration
        *1 Segment
        *2 Armature Coil Core

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Armature coil core Always 10 kΩ or higher

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

    4. A01CH9S

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      36.0 mm (1.42 in.)
      Minimum diameter
      34.0 mm (1.34 in.)

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

    5. A01CHCO

      Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

      Standard undercut depth
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

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

    6. A01CIMT

      Check that the bearing rotates smoothly.

      If necessary, replace the starter armature assembly.

    7. Inspect the commutator circle runout.


      1. A01CIYL

        Place the starter armature assembly on V-blocks.

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

        Maximum circle runout
        0.1 mm (0.00394 in.)

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

  3. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the starter yoke.


      1. A01CHT4E02
        Text in Illustration
        *1 Brush
        *2 Lead Wire

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brush - Lead wire Always Below 1 Ω

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

      2. A01CIAME02
        Text in Illustration
        *1 Brush
        *2 Starter Yoke Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brush - Starter yoke body Always 10 kΩ or higher

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

  4. INSPECT STARTER BRUSH


    1. A01CHQ2E03
      Text in Illustration
      *1 Length

      Using a vernier caliper, measure the starter brush length.

      Standard length
      18.0 mm (0.709 in.)
      Minimum length
      13.0 mm (0.512 in.)

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

      Tech Tips

      Replace all 4 starter brushes at the same time.

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the resistance.


      1. A01CJ7Y

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush holder - Negative (-) brush holder Always 10 kΩ or higher

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

    2. Inspect the load of the starter brush spring.


      1. A01CIIBE04
        Text in Illustration
        *1 Brush
        *2 Brush Spring

        Using a pull scale, measure the installed load of the spring at the exact moment the starter brush spring separates from the starter brush.

        Standard spring installed load
        18 N (1.8 kgf, 4.0 lbf)
        Minimum spring installed load
        13 N (1.3 kgf, 2.9 lbf)

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

  6. INSPECT STARTER MOTOR HOUSING


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


      1. A01CGU8E02
        Text in Illustration
        *1 Terminal M
        *2 Terminal C

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal C - Terminal M 20°C (68°F) 0.12 to 0.14 Ω

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

    2. Check the holding coil for an open circuit.


      1. A01CHDPE02
        Text in Illustration
        *1 Terminal C
        *2 Starter Motor Housing Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal C - Starter motor housing body 20°C (68°F) 1.13 to 1.25 Ω

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

    3. Check the resistance.


      1. A01CHNPE04
        Text in Illustration
        *1 Terminal M
        *2 Terminal B
        A01CHW8 Push

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

        Standard Resistance
        Tester Connection Switch Condition Specified Condition
        Terminal B - Terminal M Not pushed 10 kΩ or higher
        Pushed Below 1 Ω

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

  7. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01CHWX

      Check the starter clutch sub-assembly operation.


      1. Grip the clutch in one hand and turn only the inner sleeve with the other hand.

        Text in Illustration
        A01CHW8 Free
        A01CHIJ Lock

      2. Check that the inner sleeve turns easily in the "free" direction but cannot turn in the "lock" direction as shown in the illustration.

        If the starter clutch sub-assembly does not operate as specified, replace the starter clutch sub-assembly.

    2. A01CIP9

      Using a micrometer, measure the outside diameter of the starter clutch sub-assembly.

      Standard outside diameter
      25.0 mm (0.984 in.)
      Minimum outside diameter
      24.9 mm (0.980 in.)

      If the outside diameter is less than the minimum, replace the starter clutch sub-assembly.

  8. INSPECT STARTER DRIVE HOUSING BUSH


    1. A01CJF8

      Using a cylinder gauge, measure the inside diameter of the starter drive housing bush.

      Standard inside diameter
      25.0 mm (0.984 in.)
      Maximum inside diameter
      25.2 mm (0.992 in.)

      If the inside diameter is more than the maximum, replace the starter assembly.

  9. INSPECT STARTER CENTER BEARING BUSH


    1. A01CITI

      Using a cylinder gauge, measure the inside diameter of the starter center bearing bush.

      Standard inside diameter
      26.0 mm (1.02 in.)
      Maximum inside diameter
      26.2 mm (1.03 in.)

      If the inside diameter is more than the maximum, replace the starter assembly.

  10. INSPECT COMMUTATOR END FRAME


    1. A01CHAP

      Using a cylinder gauge, measure the inside diameter of the commutator end frame.

      Standard inside diameter
      28.0 mm (1.10 in.)
      Maximum inside diameter
      28.1 mm (1.11 in.)

      If the inside diameter is more than the maximum, replace the commutator end frame.