STARTER 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 become hot and cause injury.

    Note

    The following tests must be done within 3 to 5 seconds to prevent the coil from burning out.


    1. Mount the starter assembly in a vise between aluminum plates.

    2. Perform a pull-in test.


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

      2. B003PSJC01
        *a Terminal 50
        *b Terminal C

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

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

    3. B003PCMC01
      B003R2S Disconnect

      Perform a holding test.


      1. Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

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

    4. B003LW3C01
      B003R2S Disconnect
      B003LF2 Returns Inward

      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, replace the magnet starter switch assembly.

    5. Perform an operation test without load.


      1. Connect the lead wire to terminal C with the nut.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      2. B003SFAC01
        *a Terminal 30
        *b Terminal 50

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is extended. 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.

        Tech Tips

        Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. B003J95C01
      *a Terminal C
      *b Terminal 50
      *c Switch Body

      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
      Terminal 50 - Switch Body Below 2 Ω

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. B003NTF

      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
        18 to 24 N (1.8 to 2.4 kgf, 4.0 to 5.4 lbf)
        Minimum spring load
        12 N (1 kgf, 2.7 lbf)

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

    2. Check the resistance.


      1. B003OGC

        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.

    3. Check the brush length.


      1. B003OEBC01
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        15.5 mm (0.610 in.)
        Minimum length
        8.5 mm (0.335 in.)

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

  4. INSPECT STARTER YOKE ASSEMBLY


    1. Check the resistance.


      1. B003Q89C01
        *a Lead Wire
        *b Brush
        *c Starter Yoke Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead Wire - Brush Always Below 1 Ω
        Starter Yoke Body - Brush 10 kΩ or higher

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

    2. Check the brush length.


      1. B003R3TC01
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        15.5 mm (0.610 in.)
        Minimum length
        8.5 mm (0.335 in.)

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

  5. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

      If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

    2. Check the resistance.


      1. B003PI1C01
        *a Segment
        *b Coil Core

        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
        Segment - Coil Core 10 kΩ or higher

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

    3. B003NXK

      Check the commutator circle runout.


      1. Place the commutator 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. Check the commutator.


      1. B003MZF

        Using a vernier caliper, measure the commutator diameter.

        Standard diameter
        30.0 mm (1.18 in.)
        Minimum diameter
        29.0 mm (1.14 in.)

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

      2. B003MKC

        Using a vernier caliper, measure the undercut depth of the commutator.

        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, replace the starter armature assembly.

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. B003O99C01
      B003R2S Free
      B003LF2 Lock

      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 clutch sub-assembly.

    2. Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

      If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.