STARTER (for 1.6 kW Type) INSPECTION


  1. INSPECT STARTER ARMATURE ASSEMBLY


    1. A003GK9E02

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

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

    2. A003CFWE02

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

      Standard resistance
      10 kΩ or higher

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

    3. Check the commutator surface for dirt or burn.

      If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper.

    4. A003B78E01

      Using vernier calipers, measure the commutator length.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

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

  2. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A003HC7E01

      Using vernier calipers, measure the brush holder length.

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

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

    2. A003GV2

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

      Standard resistance
      10 kΩ or higher

      If the resistance is not as specified, replace the starter commutator end frame assembly.

  3. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planet gears, internal gear and starter clutch for wear or damage.

      If any of the gears is damaged, replace the starter center bearing clutch sub-assembly

    2. Check the starter clutch pinion gear.


      1. A003HPSE01

        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.

  4. INSPECT REPAIR SERVICE STARTER KIT


    1. A003H7P

      Check the plunger.


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

        If necessary, replace the repair service starter kit.

    2. A003D35E01

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

      Standard resistance
      1 Ω or lower

      If the result is not as specified, replace the repair service starter kit.

    3. A003E7SE01

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

      Standard resistance
      2 Ωor lower

      If the result is not as specified, replace the repair service starter kit.