STARTER INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    Note

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


    1. Perform a pull-in test.


      1. A001CCRE01
        Text in Illustration
        *a Terminal 50
        *b Terminal C

        Disconnect the field coil wire from terminal C.

      2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.

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

    2. Perform a hold-in test.


      1. A001BYYE04
        Text in Illustration
        *a Terminal C
        A001BDP Disconnect

        Disconnect the negative (-) terminal lead from terminal C while maintaining the condition specified for the pull-in test above. Check that the pinion gear remains out.

        If the clutch pinion gear moves inward, replace the starter magnetic switch assembly.

    3. Inspect the clutch pinion gear return.


      1. A0019UZE03
        Text in Illustration
        *a Disconnect

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

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

    4. Perform a no-load performance test.


      1. A001DGSE02
        Text in Illustration
        *a Terminal 50
        *b Terminal 30

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

        Torque:
        6.5 N*m  { 66 kgf*cm, 57 in.*lbf }

      2. Clamp the starter in a vise.

      3. Connect the battery and an ammeter to the starter 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
        190 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Inspect the resistance of the commutator.


      1. A001FO0

        Measure the resistance between the segments of the commutator.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Segment Always Below 1 Ω

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

      2. A001CWT

        Measure the resistance between the commutator and armature coil core.

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

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

    2. Check the surface of the commutator for dirt or burns.

      If the surface is dirty or burnt, smooth it with 400-grit sandpaper or on a lathe.

    3. A00190K

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.378 in.)
      Minimum diameter
      34.0 mm (1.339 in.)

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

    4. A001CMA

      Using a dial indicator, measure the commutator runout.

      Maximum runout
      0.05 mm (0.0020 in.)

      If the commutator runout is greater than the maximum, correct it using a lathe.

    5. A001FUE

      Measure the undercut depth of the commutator.

      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.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the resistance of the field coil.


      1. A0019JL

        Measure the resistance between the lead wire and field coil brush lead.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brush - Lead wire Always Below 1 Ω

        If the resistance is not as specified, repair or replace the starter yoke assembly.

      2. A001BEX

        Measure the resistance between the field coil brush lead and field frame.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brush - Field frame Always 10 kΩ or higher

        If the resistance is not as specified, repair or replace the starter yoke assembly.

  4. INSPECT BRUSH


    1. A001B2HE01
      Text in Illustration
      *a for Brush Holder Side
      *b for Yoke Side
      *b Length

      Using a vernier caliper, measure the brush length.

      Standard length
      15.0 mm (0.590 in.)
      Minimum length
      10.0 mm (0.394 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A00199X

      Inspect the insulation.


      1. Measure the resistance between the positive (+) and negative (-) brush holders.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush holder - Negative (-) brush holder Always 10 kΩ or higher

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

    2. A001BVZE31
      Text in Illustration
      *a Brush
      *b Brush Spring

      Inspect the load of the brush spring.


      1. Take the pull scale reading immediately after the brush spring separates from the brush.

        Standard spring installed load
        21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth of the planetary gear and starter center bearing clutch sub-assembly for wear or damage. If any planetary gear is damaged, replace the planetary gear. If any gear of the starter center bearing clutch sub-assembly is damaged, replace the starter center bearing clutch sub-assembly.

    2. A001DM9

      Check the movement of the clutch pinion gear.

      Text in Illustration
      A001BDP Free
      A001D34 Lock

      1. Rotate the clutch pinion gear clockwise, and check that it turns freely.

      2. Try to rotate the clutch pinion gear counterclockwise, and check that it locks.

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A001F9IE07
      Text in Illustration
      *a Terminal 50
      *b Terminal C

      Inspect the resistance of the pull-in coil.


      1. Measure the resistance between terminals 50 and C.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Terminal C Always Below 1.0 Ω

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

    2. A001B2EE08
      Text in Illustration
      *a Terminal 50
      *b Switch Body

      Inspect the resistance of the hold-in coil.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Switch body Always Below 2.0 Ω

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