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

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.


    1. Perform a pull-in test.


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

      2. A00YS90C01
        *1 Terminal C
        *2 Terminal 50

        Connect the battery to the starter magnetic switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

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

    2. A00YRFGC01
      A00YXOY Disconnect

      Perform a holding test.


      1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains out.

        If the clutch pinion gear moves inward, replace the starter magnetic switch assembly.

    3. A00YRX4C01
      A00YXOY Disconnect

      Inspect the clutch pinion gear return.


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

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

    4. Perform an operation test without load.


      1. Connect the lead 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. Mount the starter assembly in a vise between aluminum plates.

      3. A00YT32C01
        *1 Terminal 30
        *2 Terminal 50
        *3 Terminal C

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

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

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

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the surface of the commutator for dirt and burns.

      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 resistance of the commutator.

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


      1. A00YT3A

        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 resistance is not as specified, replace the starter armature assembly.

      2. A00YXHG

        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 resistance is not as specified, replace the starter armature assembly.

    3. Check the surface of the commutator for dirt and burns.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

    4. A00YS31

      Using a vernier caliper, measure the commutator diameter.

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

      Tech Tips

      Be sure to measure the commutator diameter at the ridges.

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

    5. Check the commutator circle runout.


      1. A00YXGBC03
        *1 Armature Shaft

        Place the armature shaft on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)

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

    6. A00YRYM

      Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

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

      Tech Tips

      Be sure to measure the commutator undercut depth at a cutout.

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

  3. INSPECT STARTER YOKE ASSEMBLY


    1. Inspect the resistance of the field coil.


      1. A00YUW4

        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 resistance is not as specified, replace the starter yoke assembly.

      2. A00YT7L

        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 resistance is not as specified, replace the starter yoke assembly.

  4. INSPECT BRUSH


    1. A00YU7NC02
      *1 Length
      *a Starter Brush Holder Assembly Side
      *b Starter Yoke Assembly Side

      Using a vernier caliper, measure the brush length.

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

      Tech Tips

      Be sure to measure the brush lengths at the protrusions.

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Inspect the insulation.


      1. A00YVK8

        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. A00YUKAC01
        *1 Brush
        *2 Brush Spring

        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
        12.3 N (1 kgf, 2.8 lbf)

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


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

      If any gear of the starter center bearing clutch sub-assembly is damaged, replace the starter center bearing clutch sub-assembly.

    2. A00YR1QC02
      *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. A00YSRW

      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. A00YUL7C02
      *1 Terminal 50
      *2 Terminal C

      Check if the pull-in coil has 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 resistance is not as specified, replace the starter magnetic switch assembly.

    3. Check if the holding coil has an open circuit.


      1. A00YX01C02
        *1 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 2 Ω

        If the resistance is not as specified, replace the starter magnetic switch assembly.