STARTER(w/ Stop And Start System) 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 a no-load performance test.


      1. A01HHSSC02
        *a Starter Body
        B0057RX 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 clutch pinion gear does not move, replace the repair service starter kit.

      3. A01HEK2C02
        *a Starter Body

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

        If the clutch pinion gear returns inward, replace the repair service starter kit.

      4. A01HEPKC02
        *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.

      5. Hold 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 ammeter (AC/DC 400A probe) to the starter assembly as shown in the illustration.

        A01HJFUC02
        *a Starter Body *b Terminal 30
        *c AC/DC 400A Probe - -

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

        Standard current
        130 A or less at 11.5 V

        If the starter assembly does not operate when terminal SL2 is connected, replace the repair service starter kit.

  2. INSPECT REPAIR SERVICE STARTER KIT

    A01HICK

    1. Check the plunger.


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

        Note


        • To avoid damaging the inside of the magnet switch, do not release the plunger quickly.

        • Do not drop the plunger.

        If necessary, replace the repair service starter kit.

    2. A01HFVBC02
      *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.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01HDY7C04
      *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 (convex part) (0.354 in.)

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

    2. A01HDU3N11

      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. A01HGTHC05
        *a Brush
        *b Brush Spring

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

        Standard spring load
        22 to 27 N (2 to 3 kgf, 4.9 to 6.1 lbf)
        Minimum spring load
        14 N (1 kgf, 3.1 lbf)

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

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01HFURC02
      *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.

    2. A01HE29C02
      *a Segment
      *b Coil 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 - 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. A01HDZP

      Check the commutator circle runout.


      1. Place the shaft of the starter armature assembly on V-blocks.

      2. Using a dial gauge, 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.

    5. A01HGBF

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29 mm (convex part) (1.14 in.)
      Minimum diameter
      28 mm (convex part) (1.10 in.)

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

    6. A01HGD0

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

      Standard undercut depth
      0.4 mm (convex part) (0.0157 in.)
      Minimum undercut depth
      0.2 mm (convex part) (0.00787 in.)

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

  5. INSPECT NO. 2 REPAIR SERVICE STARTER KIT

    A01HE2KC03
    B0057RX Free
    B0059IK Lock

    1. 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 No. 2 repair service starter kit.