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 become hot and cause injury.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a no-load performance test.


      1. A01IEIXC01
        *a Starter Body
        A01UFKZ Moves outward

        Connect the positive (+) lead to terminal SL1.

      2. Connect the negative (-) lead to the starter body and check that the clutch pinion gear moves outward.

        Note

        If the positive (+) and negative (-) leads are connected incorrectly, the IC inside of the starter inrush current reduction relay will be damaged. Be sure to connect them correctly.

        If the result is not as specified, replace the repair service starter kit.

      3. A01IJGXC01
        *a Starter Body
        A01UFKZ Disconnect
        A01UCWX Returns inward

        With the clutch pinion gear in the outward position, disconnect the negative (-) lead and check that the clutch pinion gear returns inward.

        If the result is not as specified, replace the repair service starter kit.

      4. A01IFXEC01
        *a Starter Body

        Connect the positive (+) lead to terminal SL2 of the connector and the negative (-) lead to the starter body. Check that a clicking sound is heard from the starter motor.

        If the result is not as specified, replace the repair service starter kit.

      5. Secure the starter assembly in a vise between aluminum plates.

        Note

        Ensure that the starter assembly is secured in the vise to prevent it from falling out.

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

        A01IKOHC01
        *a Starter Body *b Terminal 30
        *c AC/DC 400A Probe - -
        A01UFKZ Rotates - -

      7. Connect terminal SL2 and measure the current after the AC/DC 400A probe reading has stabilized.

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal SL2 11.5 V Below 130 A

        If the result is not as specified, replace the repair service starter kit.

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

    2. A01IGBJC03
      *a Segment

      Check the commutator for an open circuit.


      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.

    3. A01II2PC03
      *a Segment
      *b Starter Armature Core

      Check the commutator for a short circuit.


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

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

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

    4. A01IHV1C01
      *a Armature Shaft

      Check the commutator for runout.


      1. Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum Runout
        0.05 mm (0.00197 in.)

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

    5. A01IGAI

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter
      29 mm (1.1417 in.)
      Minimum Diameter
      28 mm (1.1024 in.)

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

    6. A01IKET

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard Undercut Depth
      0.4 mm (0.0157 in.)
      Minimum Undercut Depth
      0.2 mm (0.00787 in.)

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01II1PC04
      *a Length

      Check the brush length.


      1. Using a vernier caliper, measure the brush length.

        Standard Length
        14.4 mm (0.567 in.)
        Minimum Length
        9.0 mm (0.354 in.)

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

    2. A01IGA7N11

      Check the brush holder resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 Always 10 kΩ or higher

        A - D

        B - C

        		 Below 1 Ω

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

    3. Check the brush spring load.


      1. A01IGNQ

        Take a pull scale reading the instant the brush spring separates from the brush.

        Standard Spring Load
        22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)
        Minimum Spring Load
        13.8 N (1.41 kgf, 3.1 lbf)

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

  4. INSPECT STARTER CLUTCH

    A01IKKVC01
    *a Free
    *b Lock

    1. Check the clutch pinion gear.


      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 the clutch pinion gear does not operate as specified, replace the starter drive housing assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT

    A01IHOS

    1. Check the plunger.


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

        Note

        Do not drop the plunger.

        If the plunger does not operate as specified, replace the repair service starter kit.

    2. A01IH6FC02
      *a Magnet Switch Body

      Check the repair service starter kit resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal SL1 - Magnet switch body Always Below 1 Ω
        Terminal SL2 - Magnet switch body Below 2 Ω

        If the result is not as specified, replace the repair service starter kit.