STARTER(for 1.6 kW Type) 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 be hot and cause injury.

    Note

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


    1. Perform the pull-in test.


      1. Remove the nut and disconnect the lead wire from terminal C.

      2. A00YXM6C01
        *1 Terminal 50
        *2 Terminal C

        Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear extends.

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

    2. A00YUX2C01
      *1 Terminal C
      A00YXOY Disconnect

      Perform the holding test.


      1. Maintain the battery connections of the pull-in test above, but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

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

    3. A00YSTUC01
      A00YXOY Disconnect
      A00YSPP Returns Inward

      Check the clutch pinion gear return.


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

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

    4. Perform the no-load performance test.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Clamp the starter assembly in a vise.

      3. A00YWBPC01
        *1 Terminal 30
        *2 Terminal 50

        Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in the illustration.

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

        Standard current
        90 A or less at 11.5 V

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

  2. INSPECT STARTER CLUTCH


    1. A00YTV2C01
      A00YXOY Free
      A00YSPP Lock

      Check the starter clutch.


      1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.

        If necessary, replace the starter repair service starter kit.

  3. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A00YRN3

      Inspect the plunger.


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

        If necessary, replace the magnet starter switch assembly.

    2. A00YS32C01
      *1 Terminal 50
      *2 Terminal C

      Inspect the pull-in coil.


      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. A00YV56C01
      *1 Terminal 50
      *2 Switch Body

      Inspect the holding coil.


      1. 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 magnet starter switch assembly.

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. Inspect the commutator for an open circuit.


      1. A00YXQ9C01
        *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.

    2. Inspect the commutator for a short circuit.


      1. A00YUC9C01
        *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.

    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. A00YRQDC01
      *1 Length

      Using a vernier caliper, measure the commutator length.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

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

  5. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A00YXDLC01
      *1 Length

      Using a vernier caliper, measure the brush length.

      Standard length
      9.0 mm (0.354 in.)
      Minimum length
      4.0 mm (0.157 in.)

      If the length is less than the minimum, replace the starter commutator end frame assembly.

    2. A00YRLM

      Inspect the insulation.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush - Negative (-) brush Always 10 kΩ or higher

        If the result is not as specified, repair or replace the starter commutator end frame assembly.