СТАРТЕР ПРОВЕРКА
PROCEDURE
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INSPECT STARTER ASSEMBLY
CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.
Note
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.
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Perform a pull-in test.
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Remove the nut, and then disconnect the field coil lead wire from terminal C.
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Text in Illustration *1 Terminal C *2 Terminal 50 Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.
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Perform a holding test.
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Text in Illustration *1 Terminal C When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) terminal lead from terminal C. Check that the pinion gear remains out.
If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
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Inspect the clutch pinion gear return.
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Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
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Perform an operation test without load.
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Connect the field coil lead wire to terminal C with the nut.
- Torque:
- 10 N*m { 102 kgf*cm, 7 ft.*lbf }
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Mount the starter in a vise between aluminum plates.
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Text in Illustration *1 Terminal 30 *2 Terminal 50 Connect the battery and an ammeter to the starter as shown in the illustration.
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Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.
Standard current 150 A or less at 11.5 V If the result is not as specified, replace the starter assembly.
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INSPECT MAGNET STARTER SWITCH ASSEMBLY
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Check if the pull-in coil has an open circuit.
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Text in Illustration *1 Terminal C *2 Terminal 50 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 If the result is not as specified, replace the magnet starter switch assembly.
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Check if the holding coil has an open circuit.
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Text in Illustration *1 Terminal 50 Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Switch body Always Below 2 Ω If the result is not as specified, replace the magnet starter switch assembly.
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INSPECT STARTER ARMATURE ASSEMBLY
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Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
If necessary, replace the starter armature assembly.
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Inspect the commutator for an open circuit.
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Text in Illustration *1 Segment 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 If the result is not as specified, replace the starter armature assembly.
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Inspect the commutator for a short circuit.
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Text in Illustration *1 Armature Coil Core *2 Commutator Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Segment - Armature coil core Always 10 kΩ or higher If the result is not as specified, replace the starter armature assembly.
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Check the commutator circle runout.
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Place the armature shaft on V-blocks.
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Using a dial indicator, measure the circle runout.
Maximum runout 0.05 mm (0.00197 in.) If the circle runout is more than the maximum, replace the starter armature assembly.
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Using a vernier caliper, measure the commutator diameter.
Standard diameter 29.0 mm (1.14 in.) Minimum diameter 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.
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Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
Standard undercut depth 0.4 mm (0.0157 in.) Minimum undercut depth 0.2 mm (0.00787 in.) Tech Tips
Be sure to measure the commutator undercut depth at a cutout.
If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
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INSPECT STARTER BRUSH HOLDER ASSEMBLY
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Using a vernier caliper, measure the brush length.
Standard length 14.4 mm (0.567 in.) Minimum length 9.0 mm (0.354 in.) Tech Tips
Be sure to measure the brush lengths at the protrusions.
If the length is less than the minimum, replace the starter brush holder assembly.
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Inspect the load of the brush spring.
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Text in Illustration *1 Brush *2 Brush Spring Take a pull scale reading immediately after the brush spring separates from the brush.
Standard spring load 22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf) Minimum spring load 14 N (1 kgf, 3.1 lbf) If the load is less than the minimum, replace the starter brush holder assembly.
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INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
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Check the gear teeth on the planetary gears, and the internal gear and pinion gear of the starter center bearing clutch for wear or damage.
If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly.
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Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
Text in Illustration 
Free 
Lock If the result is not as specified, replace the starter center bearing clutch sub-assembly.
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