СТАРТЕР ПРОВЕРКА
PROCEDURE
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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 eithin 3 to 5 seconds to prevent the coil from burning out.
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Mount the starter assembly in a vise between aluminum plates.
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*1 Body *2 Terminal C *3 Terminal 50 Remove the nut and disconnect the lead wire from terminal C.
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Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear is extended.
If the clutch pinion gear does not move, replace the magnet starter switch assembly.
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Perform a holding test.
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*1 Body *2 Terminal C *3 Terminal 50 When the battery is connected as shown 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 returns inward, replace the magnet starter switch assembly.
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Check the operation.
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*1 Body *2 Terminal C *3 Terminal 50 Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
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Perform an operation test without load.
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Connect the lead wire to terminal C with the nut.
- Torque:
- 9.8 N*m { 100 kgf*cm, 87 in.*lbf }
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*1 Body *2 Terminal 50 *3 Terminal 30 Connect the battery and an ammeter to the starter assembly as shown in the illustration.
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Check that the starter assembly rotates smoothly and steadily while 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.
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INSPECT STARTER ARMATURE ASSEMBLY
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Check the commutator for open circuits.
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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.
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Check the commutator for ground.
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Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Segment - Coil Core Always Below 1 Ω If the result is not as specified, replace the starter armature assembly.
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Check the commutator surface for dirt and burns.
If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.
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Check the commutator for circle runout.
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Place the commutator on V-blocks.
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Using a dial indicator, measure the circle runout.
Maximum Runout 0.05 mm (0.00196 in.) If the runout is more than the maximum, replace the starter armature assembly.
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Using a vernier caliper, measure the commutator diameter.
Standard Diameter 28.0 mm (1.10 in.) Minimum Diameter 27.0 mm (1.06 in.) If the diameter is less than the minimum, replace the starter armature assembly.
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Check that the undercut portion between the segments is free of foreign matter and measure its depth.
Standard Undercut Depth 0.6 mm (0.0236 in.) Minimum Undercut Depth 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, adjust it with a hacksaw blade.
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INSPECT STARTER YOKE ASSEMBLY
*1 Field Coil Brush Lead *2 Terminal C
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Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Terminal C - Brush lead Always Below 1 Ω If the result is not as specified, replace the starter yoke assembly.
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*1 Field Coil Brush Lead *2 Starter Yoke Body Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Brush lead - Body Always 10 kΩ or higher If the result is not as specified, replace the starter yoke assembly.
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INSPECT BRUSH
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Using a vernier caliper, measure the brush length.
Standard Length 14 mm (0.551 in.) Minimum Length 9 mm (0.354 in.) If the length is less than the minimum, replace the starter brush holder assembly and the starter yoke assembly.
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INSPECT STARTER BRUSH HOLDER ASSEMBLY
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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.
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INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
*a Free *b Lock
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Hold the starter clutch and 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.
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INSPECT MAGNET STARTER SWITCH ASSEMBLY
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Check the plunger.
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Push in the plunger and check that it returns quickly to its original position.
If the result is not as specified, replace the magnet starter switch assembly.
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*1 Terminal 50 *2 Terminal C Check the pull-in coil for an open circuit.
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Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Terminal 50 - Body Always Below 1 Ω If the result is not as specified, replace the magnet starter switch assembly.
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*1 Terminal 50 *2 Magnet Starter Switch Body Check whether the holding coil has an open circuit.
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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.
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