STARTER 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. Otherwise, the cable may become hot and cause injury.

    Note

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


    1. Mount the starter 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. A002MG0E02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C
        A002OPC Moves Outward

        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, replace the magnet starter switch assembly.

    3. Perform a holding test.


      1. A002Q2NE02
        Text in Illustration
        *1 Terminal C
        A002OPC Disconnect

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

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

    4. Inspect the clutch pinion gear return.


      1. A002MMA

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

        Text in Illustration
        A002OPC Disconnect
        A002ODU 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:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      2. A002N9DE02
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

        Standard current
        Below 90 A at 11.5 V

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

  2. 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.

      If necessary, replace the starter armature assembly.

    2. Inspect the commutator for an open circuit.


      1. A002QZEE03
        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.

    3. Inspect the commutator for a short circuit.


      1. A002OC1E03
        Text in Illustration
        *1 Coil Core
        *2 Segment

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

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

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

    4. A002OLE

      Check the commutator circle runout.


      1. Place the commutator on V-blocks.

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

        Standard circle runout
        0.02 mm (0.000787 in.)
        Maximum circle runout
        0.04 mm (0.00157 in.)

        If the circle runout is more than the maximum, correct the circle runout with sandpaper (No. 400) or replace the starter armature assembly.

    5. Check the commutator diameter.


      1. A002Q7Q

        Using a vernier caliper, measure the commutator diameter.

        Standard diameter
        29.9 mm (1.17 in.)
        Minimum diameter
        28.8 mm (1.13 in.)

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

    6. Check the undercut depth.


      1. A002QFF

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

        Standard depth
        0.9 mm (0.0354 in.)
        Minimum depth
        0.4 mm (0.0157 in.)

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush length.


      1. A002PKKE02
        Text in Illustration
        *1 Length

        Using a vernier caliper, measure the brush length.

        Standard length
        10.5 mm (0.413 in.)
        Minimum length
        7.0 mm (0.276 in.)

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

    2. Inspect the brush insulation.


      1. A002QE4E05

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

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 Always 10 kΩ or higher

        A - D

        B - C

        		 Always Below 1 Ω

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

  4. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A002QK5

      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
      A002OPC Free
      A002ODU Lock

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

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A002PEAE03
        Text in Illustration
        *1 Switch Body
        *2 Return Spring
        *3 Plunger

        Install the plunger and return spring to the switch body.

    2. A002PQO

      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.

    3. Check the resistance.


      1. A002NS7E03
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

        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.

      2. A002MYTE03
        Text in Illustration
        *1 Switch Body
        *2 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 1.5 Ω

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