STARTER (for 2.7 kW Type) INSPECTION


  1. PERFORM PULL-IN/HOLDING TEST

    A01KIR2E02

    1. Disconnect the lead wire from terminal C.

      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

    2. Connect the battery to the magnetic switch as shown in the illustration.

    3. Check that the pinion gear moves outside.

    4. A01KE8UE02
      Text in Illustration
      *1 Terminal C

      Disconnect the negative lead from terminal C.

    5. Check that the magnetic clutch keeps the pinion gear moving outside.

    6. A01KIAO

      Disconnect the negative lead from the switch body.

    7. Check that the pinion gear returns.

    8. Reconnect the lead wire to the terminal C.

  2. PERFORM OPERATION TEST WITHOUT LOAD

    A01KEASE02
    Text in Illustration
    *1 Terminal 50
    *2 Terminal 30

    Note

    These tests must be performed within 5 seconds to prevent burning out the starter motor.


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

    2. Check that the pinion gear rotates smoothly.

    3. Measure the current when the pinion gear rotates.

      Standard current (at 11.5 V)
      180 A or less

      If the current is not as specified, check the starter assembly.

  3. INSPECT STARTER ARMATURE ASSEMBLY

    A01KI12E09

    1. If the surface of the commutator is dirty or burned, polish the part with sandpaper (#400) or replace the armature.

    2. Check the commutator open circuit.

      Text in Illustration
      *1 Commutator

      1. Using an ohmmeter, check that there is continuity between the segments of the commutator.

        If there is no continuity between any segment, replace the armature.

    3. A01KFQ5E10
      Text in Illustration
      *1 Commutator
      *2 Armature Core

      Check the commutator ground.


      1. Using an ohmmeter, check that there is no continuity between the commutator and armature core.

        If there is continuity, replace the armature.

    4. A01KI75

      Check the commutator circle runout.


      1. Place the armature on the V-blocks.

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

        Maximum circle runout
        0.05 mm (0.0020 in.)
        If the circle runout is greater than maximum, correct it with sandpaper (#400) or replace the armature.
    5. A01KGUL

      Using vernier calipers, measure the commutator diameter.

      Diameter
      Standard 36.0 mm (1.378 in.)
      Minimum 35.0 mm (1.339 in.)

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

    6. A01KHA4E05
      Text in Illustration
      *a Under Cut Depth

      Measure the undercut depth of commutator.

      Diameter
      Standard 0.7 mm (0.028 in.)
      Minimum 0.2 mm (0.008 in.)

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

  4. INSPECT STARTER BEARING


    1. Check that the bearings rotate smoothly.

      If necessary, replace them.

  5. INSPECT STARTER YOKE ASSEMBLY

    A01KECM

    1. Inspect for open circuit.


      1. Check that there is continuity between the terminal C wire and brushes.

        If there is no continuity, replace the starter yoke assembly. (b)

    2. A01KGNH

      Inspect for ground.


      1. Check that there is no continuity between the brushes and starter yoke body.

      2. Check that there is no continuity between the terminal C wire and starter yoke body.

        If there is continuity, replace the starter yoke assembly.

  6. INSPECT BRUSH

    A01KI10
    Text in Illustration
    *a Length

    1. Using vernier calipers, measure the brush length.

      Diameter
      Standard 20.5 mm (0.807 in.)
      Minimum 11.0 mm (0.433 in.)

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

  7. INSPECT STARTER BRUSH HOLDER ASSEMBLY

    A01KI5ME10

    1. Using an ohmmeter, check that there is no continuity between the positive and negative brush holders.

      Text in Illustration
      *1 Positive
      *2 Negative

      If there is continuity, replace the brush holder.

    2. A01KFHO

      Using a pull scale, measure the brush spring load.

      Spring load
      Standard 34.3 - 42.1 N (3.5 - 4.3 kgf, 7.7 - 9.5 lbf)
      Minimum 18.6 N (1.9 kgf, 4.2 lbf)

      If the spring load is less than the minimum, replace the brush springs.

  8. INSPECT STARTER CLUTCH SUB-ASSEMBLY

    A01KGGME12
    Text in Illustration
    *a Lock
    *b Free

    1. Check that the starter clutch operates.

      If the starter clutch is does not operate, replace it.

  9. INSPECT MAGNET STARTER SWITCH ASSEMBLY

    A01KG0ZE01
    Text in Illustration
    *1 Terminal 50
    *2 Terminal C

    1. Check the pull-in coil continuity.


      1. Using an ohmmeter, check that there is continuity between terminals 50 and C.

        If there is no continuity, replace the magnet starter switch assembly.

    2. A01KEFFE01
      Text in Illustration
      *1 Terminal 50
      *2 Switch Body

      Check the holding coil continuity.


      1. Using an ohmmeter, check that there is continuity between terminals 50 and switch body.

        If there is no continuity, replace the magnet starter switch assembly.

    3. A01KGU7E01
      Text in Illustration
      *a Wear

      Inspect the contact plate.


      1. Remove the 3 nuts, end cover, gasket and plunger.

      2. Using vernier calipers, measure the contact plate for depth of wear.

        Maximum wear
        1.6 mm (0.063 in.)
        If the depth of wear is greater than the maximum, replace the terminal kit parts.

      3. Install a new gasket, plunger and the end cover.