СТАРТЕР ПРОВЕРКА


  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

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


    1. Mount the starter assembly in a vise between aluminum plates.

    2. Perform a pull-in test.


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

      2. A003FPEE01
        Text in Illustration
        *a Terminal C
        *b Terminal 50
        A003DCD Extends

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

        If the clutch pinion gear does not extend, replace the magnet starter switch assembly.

    3. Perform a holding test.


      1. A003CHE

        Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the clutch pinion gear remains out.

        Text in Illustration
        A003DCD Disconnect

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

    4. Inspect the clutch pinion gear return.


      1. A003GD0

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

        Text in Illustration
        A003DCD Disconnect
        A003GWQ Return Inward

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

    5. Perform an operation test without load.


      1. Connect the lead wire to terminal C with the nut.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A003HLME01
        Text in Illustration
        *a Terminal 30
        *b Terminal 50
        *c AC/DC 400 A Probe

        Connect the battery and an ammeter (AC/DC 400 A probe) to the starter assembly as shown in the illustration.

        Standard current
        150 A or less at 11.5 V

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A003BG6

      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. A003DAZE01
      Text in Illustration
      *a Terminal C
      *b Terminal 50
      *c Switch Body

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Terminal 50 - Terminal C Always Below 1 Ω
      Terminal 50 - Switch body Below 2 Ω

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the resistance.


      1. A003GZZE01

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        A - B Always Below 1 Ω
        C - D
        D - E

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

    2. Check the brush length.


      1. A003C6DE01
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        10.4 mm (0.409 in.)
        Minimum length
        5.0 mm (0.197 in.)

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator surface for dirt and burns.

      If the surface is dirty or burnt, replace the starter armature assembly.

    2. Check the resistance.


      1. A003DOZE01
        Text in Illustration
        *a Segment
        *b Coil Core

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Segment Always Below 1 Ω
        Segment - Coil core 10 kΩ or higher

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

    3. Check the commutator for circle runout.


      1. A003DTR

        Place the commutator on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)

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

    4. Check the commutator.


      1. A003D8D

        Using a vernier caliper, measure the commutator diameter.

        Standard diameter (convex part)
        29.0 mm (1.14 in.)
        Minimum diameter (convex part)
        28.0 mm (1.10 in.)

        Tech Tips

        Be sure to measure the commutator diameter at the ridges.

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

    5. A003DFJ

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

      Standard undercut depth (convex part)
      0.7 mm (0.0276 in.)
      Minimum undercut depth (convex part)
      0.4 mm (0.0157 in.)

      Tech Tips

      Be sure to measure the commutator diameter at the ridges.

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

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. Check the clutch pinion gear teeth for wear or damage.

      If the clutch pinion gear teeth are damaged, replace the repair service starter kit and also inspect the flywheel ring gear for wear or damage.

    2. A003BU4

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

      Text in Illustration
      A003DCD Free
      A003GWQ Lock

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