STARTER INSPECTION

CAUTION / NOTICE / HINT

Tech Tips

When replacing the starter assembly, it is necessary to replace the starter relay as well.

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    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 be done within 3 to 5 seconds to prevent the coil from burning out.


    1. A004R3HE01
      Text in Illustration
      *a Terminal C
      *b Terminal 50

      Perform the pull-in test.


      1. Disconnect the field coil wire from terminal C.

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

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

    2. A004POOE01
      Text in Illustration
      *a Terminal C
      A004NPW Disconnect

      Perform the holding test.


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

        If the clutch pinion gear returns inward, replace the starter assembly.

    3. A004MOF

      Inspect the clutch pinion gear return.


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

        Text in Illustration
        A004NPW Disconnect

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

    4. A004TT3E04
      Text in Illustration
      *a Terminal 50
      *b Terminal 30
      *c Terminal C

      Perform the no-load performance test.


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

        Torque:
        8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

      2. Clamp the starter assembly in a vise between aluminum plates.

      3. Connect the battery and an ammeter to the starter assembly 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
        70 A or less at 11 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

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


    1. A004Q0ZE01
      Text in Illustration
      *a Segment

      Check the commutator for an open circuit.


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

        Standard resistance
        2.67 to 3.29 Ω

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

    2. Check the commutator for a short circuit.


      1. A004ST7E01
        Text in Illustration
        *a Segment
        *b Armature Core

        Measure the resistance between the segment and armature core.

        Standard resistance
        10 kΩ or higher

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

    3. 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.

    4. A004S5Y

      Check the commutator circle runout.


      1. Place the shaft of the starter armature assembly on V-blocks.

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

        Standard runout
        0.05 mm (0.00197 in.)
        Maximum runout
        0.07 mm (0.00276 in.)

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

    5. A004T9I

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      30.2 mm (1.19 in.)
      Minimum diameter
      28.9 mm (1.14 in.)

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

    6. A004O6M

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

      Standard undercut depth
      1.43 mm (0.0563 in.)
      Minimum undercut depth
      0.75 mm (0.0295 in.)

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A004P7JE03
      Text in Illustration
      *a Brush Length

      Using a vernier caliper, measure the brush length.

      Standard brush length
      12.3 mm (0.484 in.)
      Minimum brush length
      9.8 mm (0.386 in.)

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

    2. A004U0BE02

      Check the starter brush holder resistance.


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

        Standard Resistance
        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 result is not as specified, replace the starter brush holder assembly.

  4. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A004PPM

      Check the starter clutch pinion gear.


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

        Text in Illustration
        A004NPW Lock
        A004NAK Free

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

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A004P32

      Check the plunger.


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

      2. A004NPA

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

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

    2. A004T7NE03
      Text in Illustration
      *a Terminal 50
      *b Terminal C

      Check the pull-in coil.


      1. Measure the resistance between terminal 50 and terminal C.

        Standard resistance
        Below 1 Ω

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

    3. A004MK7E01
      Text in Illustration
      *a Terminal 50
      *b Magnet Switch Body

      Check the hold-in coil.


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

        Standard resistance
        Below 2 Ω

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