STARTER(for 2.7 kW Type) INSPECTION

PROCEDURE


  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

    The following tests must be done 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. A01XDVPE02
        Text in Illustration
        *a Terminal C
        *b Terminal 50
        B001CHY 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 move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    3. Perform a holding test.


      1. A01XFUG

        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
        B001CHY Disconnect

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

    4. Inspect the clutch pinion gear return.


      1. A01XE96

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

        Text in Illustration
        B001CHY Disconnect
        B001DEF Returns 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:
        24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      2. A01XG3YE01
        Text in Illustration
        *a Terminal 50
        *b Terminal 30
        *c AC/DC 400 A Probe
        B001CHY Connect

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

      3. Connect the battery and an ammeter to the starter assembly as shown in the illustration.

      4. Check that the starter rotates smoothly and steadily while the clutch pinion gear is extended. Then measure the current.

        Standard current
        180 A or less at 11.0 V

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01XF7KE02
      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. Inspect the load of the brush spring.


      1. A01XJPQ

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

        Standard spring load
        26 to 45 N (3 to 5 kgf, 5.8 to 10.1 lbf)
        Minimum spring load
        12 N (1 kgf, 2.7 lbf)

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

    2. Check the resistance.


      1. A01XKTG

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

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

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

    3. Check the brush length.


      1. A01XEFYE02
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        20.5 mm (0.814 in.)
        Minimum length
        11.0 mm (0.433 in.)

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

  4. INSPECT STARTER YOKE ASSEMBLY


    1. Check the resistance.


      1. A01XJCFE02
        Text in Illustration
        *a Lead Wire
        *b Brush
        *c Starter Yoke Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead Wire - Brush Always Below 1 Ω
        Starter Yoke Body - Brush 10 kΩ or higher

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

    2. Check the brush length.


      1. A01XCM8E01
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        20.5 mm (0.814 in.)
        Minimum length
        11.0 mm (0.433 in.)

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

  5. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

    2. Check the resistance.


      1. A01XJ3WE01
        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 circle runout.


      1. A01XFSP

        Place the armature on V-blocks.

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

        Maximum circle runout
        0.05 mm (0.00197 in.)

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

    4. Check the commutator.

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


      1. A01XG8G

        Using a vernier caliper, measure the commutator diameter.

        Standard diameter
        36.0 mm (1.42 in.)
        Minimum diameter
        35.0 mm (1.38 in.)

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

      2. A01XM9Y

        Using a dial indicator, measure the undercut depth of the commutator.

        Standard undercut depth
        0.7 mm (0.0276 in.)
        Minimum undercut depth
        0.2 mm (0.00787 in.)

        If the undercut depth is less than the minimum, correct it with a hacksaw blade.

    5. Inspect the armature bearings.


      1. Check that the armature bearings rotate smoothly.

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

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01XJDG

      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
      B001CHY Free
      B001DEF Lock

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

    2. Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

      If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.