STARTER (for 2.2 kW Type) INSPECTION


  1. 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. A01BCG8E01

      Inspect the commutator for an open circuit.


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

        Standard
        1 Ω or lower

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

    2. A01BF9YE01

      Inspect the commutator for a short circuit.


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

        Standard
        10 kΩ higher

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

    3. A01BA99E01

      Inspect the commutator circle runout.


      1. Place the armature on the V-blocks.

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

        Maximum circle runout
        0.05 mm (0.0020 in.)

        • If the runout is greater than the maximum, correct with sandpaper (#400) or replace the armature assembly.

    4. A01BG1YE01

      Using vernier calipers, measure the commutator diameter.

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

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

    5. A01BHKYE01

      Measure the undercut depth of the commutator.

      Standard depth
      0.7 mm (0.028 in.)
      Minimum depth
      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.

  2. INSPECT STARTER YOKE ASSEMBLY


    1. A01BDOVE01

      Inspect for an open circuit.


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

        Standard
        1 Ω or lower

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

    2. A01BB61E01

      Inspect for a short circuit.


      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 stater yoke body.

        Standard
        10 kΩ or higher

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

  3. INSPECT BRUSH


    1. A01BF6RE01

      Using vernier calipers, measure the brush length.

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

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01BCS6E01

      Using an ohmmeter, check that there is continuity between the positive and negative brush holders.

      Standard
      10 kΩ or higher

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

    2. A01BCAFE02

      Using a pull scale, measure the brush spring load.

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

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

  5. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01BHVEE01

      Check that the starter clutch operates.


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

  6. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01BGD4E01

      Inspect the pull-in coil resistance.


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

        Standard
        1 Ω or lower

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

    2. A01BEFLE01

      Inspect the holding coil continuity.


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

        Standard
        2 Ω or lower

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