STARTER (for Cold Area) INSPECTION


  1. INSPECT STARTER ARMATURE ASSEMBLY


    1. A0136IFE01

      Check the commutator for open circuit.


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

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

    2. A0137UME01

      Check the commutator for ground.


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

        If there is continuity, replace the starter armature.

    3. 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.

    4. A01377U

      Check for the commutator circuit runout.


      1. Place the commutator on V-blocks.

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

        Standard runout
        0.02 mm (0.0008 in.)
        Maximum runout
        0.04 mm (0.0016 in.)

        If the runout is greater than maximum, replace the armature.

    5. A0138V7

      Using vernier calipers, measure the commutator diameter.

      Standard diameter
      29.9 mm (1.1772 in.)
      Minimum diameter
      28.8 mm (1.1339 in.)

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

    6. A0135YW

      Using vernier calipers, measure the undercut depth of the commutator.

      Standard depth
      0.9 mm (0.0354 in.)
      Limit depth
      0.4 mm (0.0157 in.)

  2. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A0136VT

      Using vernier calipers, measure the brush length.

      Standard length
      10.5 mm (0.4134 in.)
      Minimum length
      7.0 mm (0.2756 in.)

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

    2. A0138V0E01

      Check the brush holder.


      1. Using an ohmmeter, measure the resistance between the brushes.

        Standard
        Tester Connection Specified Condition
        A-B 10 kΩ or higher
        A-C 10 kΩ or higher
        A-D Below 1 Ω
        B-C Below 1 Ω
        B-D 10 kΩ or higher
        C-D 10 kΩ or higher

        If the standard is not met, replace the starter brush holder.

  3. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A0137SZE01

      Check the starter clutch pinion gear.


      1. Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

        If necessary, replace the starter center clutch.

  4. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01389CE01

      Check the plunger.


      1. Install the plunger and spring onto the switch body.

    2. A0137OY

      Push in the plunger and check that it returns quickly to its original position.

      If necessary, replace the magnet starter switch.

    3. A0137DOE01

      Check the pull-in coil for open circuit.


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

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

    4. A0138RNE01

      Check whether the holding coil has an open circuit.


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

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