STARTER (for 2.7 kW Type) INSPECTION


  1. INSPECT STARTER

    Note

    The following tests must be performed within 3 to 5 seconds to prevent the coil from burning out.


    1. A003HA0E01

      Perform the pull-in test.


      1. Disconnect the field coil lead wire from terminal C.

      2. A003EZME01

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

    2. A003GHWE01

      Perform the hold test.


      1. Disconnect the negative (-) lead from terminal C while sustaining the above condition (a). Check that the pinion gear remains extended.

    3. A003CUIE01

      Check the return operation.


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

    4. A003HA0

      Perform the operation test without any load.


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

        Torque:
        24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      2. A003AW4E01

        Clamp the starter in a vise.

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

      4. Check that the ammeter indicates the specified current.

        Specified current
        180 A or less at 11.5 V

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A003FB5E01

      Using an ohmmeter, measure the resistance between the segments of the commutator.

      Standard resistance
      Below 1 Ω

      If the results is not as specified, replace the starter armature.

    2. A003DOAE01

      Using an ohmmeter, check the resistance between the commutator and armature coil core.

      Standard resistance
      10 MΩ or higher

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

    3. A003CZX

      Check the commutator for circuit runout.


      1. Place the commutator on V-blocks.

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

        Maximum runout
        0.05 mm (0.002 in.)

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

    4. A003HDE

      Using vernier calipers, measure the commutator diameter.

      Standard diameter
      36.0 mm (1.417 in.)
      Minimum diameter
      35.0 mm (1.378 in.)

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

    5. A003BO0

      Check that the undercut portion between the segments is free of foreign objects and measure its depth.

      Standard undercut depth
      0.7 mm (0.028 in.)
      Minimum undercut depth
      0.2 mm (0.008 in.)

      If the undercut depth is less than the minimum, correct it with a hacksaw blade.

    6. Check the bearing.


      1. Check that the bearing rotate smoothly.

        If necessary, replace the starter armature assembly.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A003E7OE01

      Using an ohmmeter, measure the resistance between the terminal C and brush.

      Standard resistance
      Below 1 Ω

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

    2. A003H78E01

      Using an ohmmeter, check the resistance between the starter yoke body and brushes.

      Standard resistance
      10 MΩ or higher

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A003HXFE01

      Using vernier calipers, measure the brush length.

      Standard length
      20.5 mm (0.807 in.)
      Minimum length
      11.0 mm (0.433 in.)

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

    2. A003HYSE01

      Check the pull scale reading as soon as the brush spring is separated from the brush.

      Standard spring load
      34.3 to 42.1 N (3.5 to 4.3 kgf, 7.7 to 9.5 lbf)
      Minimum spring load
      18.6 N (1.9 kgf, 4.2 lbf)

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

    3. A003GIOE01

      Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

      Standard resistance
      10 MΩ or higher

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

  5. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A003CF2E01

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

      If necessary, replace the starter clutch.

  6. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A003I2QE01

      Using an ohmmeter, measure the resistance between terminals 50 and C.

      Standard resistance
      Below 1 Ω

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

    2. A003AEFE01

      Using an ohmmeter, measure the resistance between terminal 50 and the magnet switch body.

      Standard resistance
      Below 1 Ω

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