STARTER (for 1.4 kW Type) INSPECTION


  1. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Inspect the pull-in coil.


      1. A01BE6IE03

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Terminal C Always Below 1 Ω

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

    2. Inspect the holding coil.


      1. A01BCLRE03

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Switch body Always Below 2 Ω

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

  2. INSPECT BRUSH


    1. A01BBM8E06

      Using a vernier caliper, measure the brush length.

      Standard length
      15.5 mm (0.610 in.)
      Minimum length
      8.5 mm (0.335 in.)

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush spring load.


      1. A01BCAFE10

        Take a pull scale reading immediately after the brush spring separates from the brush.

        Standard spring load
        18 to 24 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf)
        Minimum spring load
        12 N (1 kgf, 2.7 lbf)

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

    2. Inspect the insulation.


      1. A01BB12E03

        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.

  4. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the field coil.


      1. A01BGE1E01

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

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

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

      2. A01BH58E01

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

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

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

  5. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

    2. Inspect the commutator for an open circuit.


      1. A01BE1PE03

        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. A01BEILE03

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

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

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

    4. Check the commutator circle runout.


      1. A01BB9PE01

        Place the commutator on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. A01BAIZE01

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      30.0 mm (1.18 in.)
      Minimum diameter
      29.0 mm (1.14 in.)

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

    6. A01BGJB

      Using a vernier caliper, measure the undercut depth of the commutator.

      Standard undercut depth
      0.6 mm (0.0236 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. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01BBQRE01

      Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

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

    2. Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

      If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.