STARTING SYSTEM INSPECTION


  1. INSPECT STARTER ASSEMBLY (for 1.4 kW Type)

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, 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.


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

    2. Perform a pull-in test.


      1. Remove the nut, and then disconnect the field coil lead wire from terminal C.

      2. A01BBTKE03

        Connect the battery to the magnetic starter switch as shown in the illustration. Check that the clutch pinion gear extends.

        If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    3. Perform a holding test.


      1. A01BHDBE01

        Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained.

        If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    4. Inspect the clutch pinion gear return.


      1. A01BGR3

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

        If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    5. Perform an operation test without load.


      1. Connect the field coil lead wire to terminal C.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      2. A01BC7EE01

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.

        Specified current
        90 A or less at 11.5 V

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

        Tech Tips

        Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

  2. INSPECT STARTER ASSEMBLY (for 1.6 kW Type)

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, 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.


    1. Perform the pull-in test.


      1. A01BGKFE02

        Remove the nut, disconnect the field coil lead wire from terminal C.

      2. A01BCTME02

        Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear is extended.

    2. Perform the holding test.


      1. A01BCDHE02

        Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained.

    3. Check the return operation.


      1. A01BGLTE02

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

    4. Perform the operation test without load.


      1. Connect the field coil lead wire to terminal C.

        Torque:
        10 N*m  { 102 kgf*cm, 7.4 ft.*lbf }

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

    6. A01BF0FE02

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

    7. Check that the ammeter indicates the specified current.

      Specified current
      90 A or less at 11.5 V