СТАРТЕР ПРОВЕРКА

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 became 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 then disconnect the lead wire from terminal C.

      2. A01XF8WE01
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        Connect the battery to the magnet starter switch 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. A01XGITE01
        Text in Illustration
        *1 Terminal C

        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 extended.

        If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    4. Inspect the clutch pinion gear return.


      1. A01XGMK

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

        If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    5. Perform an operation test without load.


      1. Connect the field coil lead wire to terminal C.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      2. A01XM4LE01
        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 extended. Then measure the current.

        Specified current
        120 A or less at 11.5 V

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

        Tech Tips

        Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Inspect the pull-in coil.


      1. A01XGGUE03
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal C - Terminal 50 Always Below 1 Ω

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

    2. Inspect the holding coil.


      1. A01XLWLE03
        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
        Switch body - Terminal 50 Always Below 2 Ω

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

  3. INSPECT BRUSH


    1. A01XDCNE01
      Text in Illustration
      *1 Length
      *a Brush Holder Side
      *b Starter Yoke Side

      Using a vernier caliper, measure the brush length.

      Standard brush length
      16.5 mm (0.650 in.)
      Minimum brush length
      9.0 mm (0.354 in.)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01XF53

      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.

    2. Check the brush spring load.


      1. A01XGNFE28
        Text in Illustration
        *1 Brush Spring
        *2 Brush

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

        Standard spring load
        27 to 32 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)
        Minimum spring load
        18 N (2 kgf, 4.0 lbf)

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

  5. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect for an open circuit.


      1. A01XKBL

        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. Inspect for a short circuit.


      1. A01XLGO

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

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

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

  6. 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. Replace the armature if necessary.

    2. Inspect the commutator for an open circuit.


      1. A01XMA5E03
        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. A01XK6XE03
        Text in Illustration
        *1 Segment
        *2 Coil Core

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

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

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

    4. A01XJTJ

      Inspect the commutator circle runout.


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

    5. A01XFDS

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.38 in.)
      Minimum diameter
      34.0 mm (1.34 in.)

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

    6. A01XLU8

      Measure the undercut depth of the commutator.

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

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

    7. Inspect the bearings.


      1. Check that the bearing rotates smoothly.

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

  7. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01XE94

      Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the 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.