STARTER INSPECTION


  1. INSPECT STARTER ASSEMBLY

    Note

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.


    1. Perform a pull-in test.


      1. Remove the nut and disconnect the lead wire from terminal C.

      2. A01EKNBE02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

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

        If the clutch pinion gear does not move, replace the magnetic switch assembly.

    2. A01EKE5E11
      Text in Illustration
      *1 Disconnect
      *2 Terminal C

      Perform a hold-in test.


      1. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

        If the clutch pinion gear returns inward, replace the magnetic switch assembly.

    3. A01EK3VE06
      Text in Illustration
      *1 Disconnect

      Perform a clutch pinion gear return test.


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

        If the clutch pinion gear does not return, replace the magnetic switch assembly.

    4. A01EK0RE08
      Text in Illustration
      *1 Terminal 30
      *2 Terminal 50

      Perform a no-load performance test.


      1. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Clamp the starter in a vise.

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

      4. Check that the starter rotates smoothly and steadily while the pinion gear is moving out. Then measure the current.

        Standard current
        90 A or less at 11.5 V

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

  2. INSPECT MAGNETIC SWITCH ASSEMBLY


    1. A01EJWE

      Check the plunger.


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

        If necessary, replace the magnetic switch assembly.

    2. A01ELWPE17
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

      Check if the pull-in coil has an open circuit.


      1. Measure the resistance between terminals 50 and C.

        Standard resistance
        Below 1 Ω

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

    3. A01EJGXE14
      Text in Illustration
      *1 Terminal 50
      *2 Body

      Check if the hold-in coil has an open circuit.


      1. Measure the resistance between terminal 50 and the switch body.

        Standard resistance
        Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

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


    1. Check the commutator for contamination and burns on its surface.

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

    2. A01EMKLE15
      Text in Illustration
      *1 Segment

      Check if the commutator has an open circuit.


      1. Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1 Ω

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

    3. A01EMLQE10
      Text in Illustration
      *1 Commutator
      *2 Coil Core

      Check if the commutator is grounded.


      1. Measure the resistance between the commutator and armature coil core.

        Standard resistance
        10 kΩ or higher

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

    4. A01ELLVE17
      Text in Illustration
      *1 Length

      Using a vernier caliper, measure the commutator length.

      Standard length
      3.1 to 3.8 mm (0.122 to 0.149 in.)
      Maximum length
      3.8 mm (0.149 in.)

      If the length is greater than the maximum, replace the starter armature assembly.

  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01EJ66E13
      Text in Illustration
      *1 Length

      Using a vernier caliper, measure the brush length.

      Standard length
      4.0 to 9.0 mm (0.158 to 0.354 in.)
      Minimum length
      4.0 mm (0.158 in.)

      If the length is less than the minimum, replace the end frame assembly.

    2. A01EKP5E14

      Check the brush insulation.


      1. Measure the resistance between the positive (+) and negative (-) brushes.

        Standard resistance
        10 kΩ or higher

        If the result is not as specified, replace the end frame assembly.

  5. INSPECT STARTER CLUTCH


    1. A01ELHAE10
      Text in Illustration
      *1 Lock
      *2 Free

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

      If necessary, replace the starter drive housing assembly.