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. A01M1GR

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

      2. A01M24GC01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        A01M03W Moves outward

        Connect a battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear moves outward.

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

    2. A01M0AVC01
      *a Terminal 50
      *b Terminal C
      *c Starter Body
      A01M03W Disconnect

      Perform a hold-in test.


      1. While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

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

    3. A01M3EXC01
      *a Terminal 50
      *b Starter Body
      A01M03W Disconnect
      A01LZQW Returns inward

      Perform a return test.


      1. 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.

    4. Perform a no-load performance test.


      1. A01M1GR

        Connect the field coil lead wire to terminal C with the nut. Make sure that the field coil lead wire is not grounded.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

        Note

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

      3. A01M0FOC01
        *a Terminal 30
        *b Terminal 50
        *c Starter Body
        A01M03W Rotates

        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 clutch pinion gear operates.

      4. Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving 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 V Below 70 A

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01LY5S

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

        If the plunger does not operate as specified, replace the magnet starter switch assembly.

    2. A01LUZ9C01
      *a Terminal 50
      *b Terminal C

      Check the pull-in coil for an open circuit.


      1. 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.

    3. A01LXKMC01
      *a Terminal 50
      *b Magnet Switch Body

      Check the holding coil for an open circuit.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 -Magnet switch body Always Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If there is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

    2. A01LUVFC01
      *a Segment

      Check the commutator for an open circuit.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Segment Always 2.67 to 3.29 Ω

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

    3. A01LYHRC01
      *a Segment
      *b Starter Armature Core

      Check the commutator for a short circuit.


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

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

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

    4. A01LVD1C01
      *a Armature Shaft

      Check the commutator for runout.


      1. Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Standard Runout
        0.05 mm (0.00197 in.)
        Maximum Runout
        0.07 mm (0.00276 in.)

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

    5. A01LUTY

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter
      30.2 mm (1.19 in.)
      Minimum Diameter
      28.9 mm (1.14 in.)

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

    6. A01M1YD

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

      Standard Undercut Depth
      1.43 mm (0.0563 in.)
      Minimum Undercut Depth
      0.75 mm (0.0295 in.)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01M2SAC02
      *a Length

      Check the brush length.


      1. Using a vernier caliper, measure the brush length.

        Standard Length
        12.3 mm (0.484 in.)
        Minimum Length
        9.8 mm (0.386 in.)

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

    2. A01M2D4E04

      Check the brush holder resistance.


      1. 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

        		 Below 1 Ω

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

  5. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01M1EVC01
      *a Free
      *b Lock

      Check the clutch pinion gear.


      1. 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.

        If the clutch pinion gear does not operate as specified, replace the starter clutch sub-assembly.