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. If not, the cable may become hot and cause injury.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a pull-in test.


      1. Remove the nut and disconnect the field coil wire from terminal C.

      2. A00Y52CC02
        *a Terminal C
        *b Terminal 50

        Connect the battery to the starter magnetic switch assembly as shown in the illustration.

      3. Check that the clutch pinion gear moves outward.

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

    2. A00Y8GQ

      Perform a hold-in test.


      1. 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 moves outward.

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

    3. A00YAMQ

      Check return operation.


      1. 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. 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, 58 in.*lbf }

      2. Clamp the starter assembly in a vise between aluminum plates.

        Note

        Ensure that the starter is secured in the vise to prevent it from falling out.

      3. A00Y79OC02
        *a Terminal 30
        *b Terminal 50
        *c Terminal C

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

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter rotates smoothly and steadily with the clutch pinion gear moved outward. Measure the current according to the value(s) in the table below.

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal 50 11.5 V Below 190 A

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for an open circuit.


      1. A00Y9P9

        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.

    2. Check the commutator for a short circuit.


      1. A00Y64Y

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Commutator - Armature coil core Always 10 kΩ or higher

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

    3. Check the commutator appearance.

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

    4. Check the commutator for runout.


      1. A00Y9OSC04
        *a Armature Shaft

        Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Standard Runout
        0.02 mm (0.000787 in.)
        Maximum Runout
        0.05 mm (0.00197 in.)

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

    5. A00Y53P

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter
      35.0 mm (1.37 in.)
      Minimum Diameter
      34.0 mm (1.34 in.)

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

    6. A00Y931

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      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, adjust it with a hacksaw.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the resistance of the field coil.


      1. A00Y65T

        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

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

      2. A00Y7HS

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brush - Starter yoke body Always 10 kΩ or higher

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

  4. INSPECT BRUSH


    1. A00Y4XDC01
      *A Brush Holder Side
      *B Yoke Side
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard Length
      15.0 mm (0.591 in.)
      Minimum Length
      9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Inspect the insulation.


      1. A00Y6S6

        Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

        Standard Resistance
        10 kΩ or higher

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

    2. Inspect the load of the brush spring.


      1. A00Y9VG

        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 to 3 kgf, 4.8 to 6.2 lbf)
        Minimum Spring Installed Load
        12 N (1 kgf, 2.7 lbf)

        If the installed load is less than the minimum, replace the brush springs.

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Inspect the gear teeth of the planetary gears and internal gear of the starter center bearing clutch sub-assembly for wear or damage.

      If damaged, replace the planetary gears or starter center bearing clutch sub-assembly. Also check the planetary gears for wear and damage.

    2. A00Y5OZC01
      *a Free
      *b Lock

      Check the movement of the clutch pinion gear.


      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 STARTER MAGNETIC SWITCH ASSEMBLY


    1. A00Y5RU

      Check the plunger.


      1. Push in the plunger and check that it returns quickly to its original position.

        If necessary, replace the starter magnetic switch assembly.

    2. Check the pull-in coil for an open circuit.


      1. A00YACMC03
        *a Terminal 50
        *b 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 starter magnetic switch assembly.

    3. Inspect the resistance of the hold-in coil.


      1. A00Y50TC03
        *a Terminal 50
        *b Switch Body

        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 starter magnetic switch assembly.