STARTER (for 2.2 kW Type) INSPECTION


  1. INSPECT STARTER ARMATURE ASSEMBLY


    1. A003GSR

      Measure the resistance.


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

        Standard Resistance
        Tester Connection Connection Specified Condition
        Segment - Segment Always Below 1.7 Ω

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

      2. A003DJ1

        Measure the resistance between a segment of the commutator and armature coil core.

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

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

    2. A003HBV

      Inspect the commutator circle runout.


      1. Place the commutator on V-blocks.

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

        Standard circle runout
        0.02 mm (0.000787 in.)
        Maximum circle runout
        0.04 mm (0.00157 in.)

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

    3. A003GVY

      Using a vernier caliper, measure the commutator diameter.

      Standard commutator diameter
      32.2 mm (1.27 in.)
      Minimum commutator diameter
      31.1 mm (1.22 in.)

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

    4. A003CZL

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

      Standard undercut depth
      0.9 mm (0.0354 in.)
      Minimum undercut depth
      0.4 mm (0.0157 in.)

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

  2. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A003IAZ

      Using a vernier caliper, measure the brush length.

      Standard brush length
      14.0 mm (0.551 in.)
      Minimum brush length
      9.0 mm (0.354 in.)

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

    2. A003G5NE01

      Check the brush holder.


      1. Measure the resistance between the brushes.

        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.

  3. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A003BIIE01

      Check the starter clutch pinion gear.


      1. 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.

  4. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A003HOEE01

      Check the plunger.


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

      2. A003D1T

        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 assemby.

    2. A003DRSE01

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


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

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

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

    3. A003CB1E01

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


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

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

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