СТАРТЕР (для моделей без системы запуска и останова) 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.

    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. Mount the starter in a vise between aluminum plates.

    2. Perform the pull-in test.


      1. Remove the nut and disconnect the lead wire from the magnet starter switch assembly.

      2. A01CYA7C03
        *a Terminal 50
        *b Terminal C

        Connect the battery to the magnet starter switch assembly as shown in the illustration. Then check that the clutch pinion gear moves outward.

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

    3. A01CY3NC03
      *a Terminal C
      A01CX8N Disconnect

      Perform the 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 pinion gear remains out.

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

    4. A01CXG5C02
      A01CX8N 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 return inward, replace the magnet starter switch assembly.

    5. A01CYNEC03
      *a Terminal 50
      *b Terminal 30

      Perform an operation test without load.


      1. Connect the lead wire to the magnet starter switch assembly with the nut.

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

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

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

        Standard current
        150 A or less at 11.5 V

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01CX21

      Check the operation.


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

        If necessary, replace the magnet starter switch assembly.

    2. A01CYBGC03
      *a Terminal 50
      *b 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 result is not as specified, replace the magnet starter switch assembly.

    3. A01CXJEC03
      *a Terminal 50

      Check if the holding 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 - body Always Below 2 Ω

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

  3. 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. A01CXKN

      Inspect the resistance of the commutator.


      1. 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. A01CXCE

        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. A01CYFJ

      Check the commutator circle runout.


      1. 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.

    4. A01CWK2

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.14 in.)
      Minimum diameter
      28.0 mm (1.10 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. A01CX9B

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

      Standard undercut depth
      0.4 mm (0.0157 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.

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01CX7Q

      Using a vernier caliper, measure the brush length.

      Standard length
      14.4 mm (0.567 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.

    2. A01CY06C02
      *1 Brush
      *2 Brush Spring

      Inspect the load of the brush spring.


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

        Standard spring load
        22.3 to 27.3 N (2 to 3 kgf, 5.0 to 6.1 lbf)
        Minimum spring load
        13.8 N (1 kgf, 3.1 lbf)

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

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


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

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

    2. A01CXFXC01
      A01CX8N Free
      A01CX40 Lock

      Hold the starter center bearing 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 the result is not as specified, replace the starter center bearing clutch sub-assembly.