STARTER INSPECTION

PROCEDURE

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.

Perform a pull-in test.
1. Remove the nut, and disconnect the field coil lead wire from terminal C.
2. *a Terminal 50
  
  *b Terminal C
  
  Connect the battery to the magnet starter 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 magnet starter switch assembly.
*a Terminal 50

*b Terminal C

Perform a hold-in test.
1. Check that the pinion gear does not return inward after the cable is disconnected from terminal C.
  
  If the clutch pinion gear returns inward, replace the magnet starter switch assembly.
*a Terminal 50

*b Terminal C

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 magnet starter switch assembly.

Perform a no-load performance test.

Connect the field coil lead wire to terminal C with the nut.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
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.
*a Terminal 30

*b Terminal 50

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

Note

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

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 90 A

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

INSPECT STARTER ARMATURE ASSEMBLY

segment

Check the commutator for an open circuit.

Using an ohmmeter, 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.

*a	Armature Coil
*b	Commutator

Check the commutator for a short circuit.

Using an ohmmeter, 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.

Check the commutator appearance.

If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe.
Check the commutator for runout.
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the runout.
  
  Standard Runout
  
  0.02 mm (0.000787 in.)
  
  Maximum Runout
  
  0.04 mm (0.00157 in.)
  
  If the runout is greater than the maximum, replace the starter armature assembly.
Using a vernier caliper, measure the commutator diameter.

Standard Diameter

29.9 mm (1.18 in.)

Minimum Diameter

28.8 mm (1.13 in.)

If the diameter is less than the minimum, replace the starter armature assembly.
Check that the undercut portion between the segments is free of foreign matter and measure its depth.

Standard Undercut Depth

0.9 mm (0.0354 in.)

Minimum Undercut Depth

0.4 mm (0.0157 in.)

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

Standard Runout
0.02 mm (0.000787 in.)

Maximum Runout
0.04 mm (0.00157 in.)

Standard Diameter
29.9 mm (1.18 in.)

Minimum Diameter
28.8 mm (1.13 in.)

Standard Undercut Depth
0.9 mm (0.0354 in.)

Minimum Undercut Depth
0.4 mm (0.0157 in.)

INSPECT STARTER BRUSH HOLDER ASSEMBLY

*a 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.

Standard Length
10.5 mm (0.413 in.)

Minimum Length
7.0 mm (0.276 in.)

Check the brush holder.

Using an ohmmeter, measure the resistance between the brushes.

Standard Resistance

Tester Connection	Specified Condition
A - B	10 kΩ or higher
A - C	10 kΩ or higher
A - D	Below 1 Ω
B - C	Below 1 Ω
B - D	10 kΩ or higher
C - D	10 kΩ or higher

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

INSPECT STARTER CLUTCH SUB-ASSEMBLY
1. *a Free
  
  *b Lock
  
  Check the starter clutch pinion gear.
  1. While holding the starter clutch sub-assembly, rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
    
    If necessary, replace the starter clutch sub-assembly.

INSPECT MAGNET STARTER SWITCH ASSEMBLY

*a	Plunger
*b	Return Spring
*c	Switch Body

Check the plunger.

Install the plunger and return spring onto the switch body.

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

If necessary, replace the magnet starter switch assembly.
*a Terminal 50

*b Terminal C

Check the pull-in coil for an open circuit.
1. Using an ohmmeter, measure the resistance between terminals 50 and C.
  
  Standard Resistance
  
  Below 1 Ω
  
  If the result is not as specified, replace the magnet starter switch assembly.
*a Switch Body

*b Terminal 50

Check the holding coil for an open circuit.
1. Using an ohmmeter, measure the resistance between terminal 50 and the switch body.
  
  Standard Resistance
  
  Below 1.5 Ω
  
  If the result is not as specified, replace the magnet starter switch assembly.

*a	Free
*b	Lock