STARTER (for 2.2 kW Type) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    A01KGH9E02
    Text in Illustration
    *1 Terminal C
    *2 Terminal 50

    1. Perform the pull-in and holding test.


      1. Disconnect the lead wire from terminal C.

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

      3. Check that the pinion gear moves outside.

      4. A01KF6GE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        Disconnect the negative lead from terminal C.

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

      6. A01KGV8

        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. A01KEIVE02
      Text in Illustration
      *1 Terminal 30

      Perform the operation test without load.

      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.

      2. Check that the pinion gear rotates smoothly.

      3. Measure the current when the pinion gear rotates.

        Standard current (at 11.5 V):
        Starter type Current
        2.2 kW 120 A or less

        If the current is not standard, check the starter assembly.

  2. INSPECT STARTER ARMATURE ASSEMBLY

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


    1. A01KEEEE03
      Text in Illustration
      *1 Commutator

      Check the commutator open circuit.


      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 assembly.

    2. A01KFBGE03

      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 assembly.

    3. A01KH1F

      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 assembly.

    4. A01KFMG

      Using vernier calipers, measure the commutator diameter.

      Diameter
      Standard 35.0 mm (1.378 in.)
      Minimum 34.0 mm (1.339 in.)

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

    5. A01KHA4

      Measure the undercut depth of commutator.

      Depth
      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.

    6. Inspect the bearings.


      1. Check that the bearing rotates smoothly. If necessary, replace them.

  3. INSPECT STARTER YOKE ASSEMBLY

    A01KFF9

    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.

    2. A01KESX

      Inspect for ground.


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

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

        If there is continuity, replace the starter yoke assembly.

  4. INSPECT BRUSH

    A01KIJIE03
    Text in Illustration
    *a Length

    1. Using vernier calipers, measure the brush length.

      Brush length
      Standard 16.5 mm (0.650 in.)
      Minimum 9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

    A01KI5M

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

      If there is continuity, replace the brush holder.

    2. A01KFHO

      Using a pull scale, measure the brush spring load.

      Spring load
      Standard 26.5 - 32.3 N (2.7 - 3.3 kgf, 6.0 - 7.3 lbf)
      Minimum 17.6 N (1.8 kgf, 4.0 lbf)

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

  6. 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.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY

    A01KI14E01
    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. A01KGTPE01
      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. A01KHR2E01
      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
        0.9 mm (0.035 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.