STARTER INSPECTION

Info Added 2017-10-06

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 pull-in test.


      1. A001SYO

        Remove the nut, and disconnect the field coil lead wire from terminal C.

      2. A001TT9C01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B00495X Moves outward

        Connect a battery to the magnet starter switch assembly as shown in the illustration. Check that the pinion gear moves outward.

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

    2. Perform a hold-in test.


      1. A001U74C01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B00495X Disconnect

        While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the pinion gear does not return inward.

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

    3. Perform a return test.


      1. A001Y2BC01
        *a Terminal 50
        *b Terminal C
        *c Starter Body
        B00495X Disconnect
        B0049DE Returns inward

        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.

    4. Perform a no-load performance test.


      1. A001TZB

        Connect the field coil lead wire to terminal C with the nut. Make sure that the field coil lead wire is not grounded.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      2. 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.

      3. A001UXPC01
        *a Terminal 30
        *b Terminal 50
        *c Starter Body
        B00495X Rotates

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

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter assembly operates smoothly and steadily while the pinion gear is moving outward.

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

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive (+) terminal - Terminal 30 - Terminal 50 11.5 V Below 90 A

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A001SHR

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

        If the plunger does not operate as specified, replace the magnet starter switch assembly.

    2. A001WV9C01
      *a Terminal 50
      *b Terminal C

      Check the pull-in coil for 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. A001XWFC01
      *a Terminal 50
      *b Magnet Starter Switch Assembly Body

      Check the holding coil for 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 -Magnet switch 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 commutator appearance.

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

    2. A001XM1C01
      *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. A001UWNC01
      *a Segment
      *b Starter Armature 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 - Starter armature coil core Always 10 kΩ or higher

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

    4. A001UAYC01
      *a Armature Shaft

      Check the commutator for runout.


      1. Place the armature shaft on V-blocks.

      2. Using a dial indicator, measure the runout.

        Standard Runout
        0.02 mm (0.000787 in.)
        Maximum Runout
        0.04 mm (0.00157 in.)

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

    5. A001SH9C02
      *a Diameter

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter
      25.9 mm (1.0197 in.)
      Minimum Diameter
      24.9 mm (0.9803 in.)

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

    6. A001SXEC02
      *a Undercut depth

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

      Standard Undercut Depth
      0.9 mm (0.0354 in.)
      Minimum Undercut Depth
      0.4 mm (0.0157 in.)

      If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A001XOUC01
      *a Length

      Check the brush length.


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

        Standard Length
        10.2 mm (0.402 in.)
        Minimum Length
        7.0 mm (0.276 in.)

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

    2. A001X1VE04

      Check the brush holder resistance.


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

        Standard Resistance
        Tester Connection Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 10 kΩ or higher

        A - D

        B - C

        		 Below 1 Ω

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

  5. INSPECT PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A001TO3C01
      *a Free
      *b Lock

      Check the clutch gear.


      1. While holding the planet carrier shaft sub-assembly, rotate the clutch gear counterclockwise, and check that it turns freely. Try to rotate the clutch gear clockwise and check that it locks.

        If the clutch gear does not operate as specified, replace the planet carrier shaft sub-assembly.

  6. INSPECT STARTER YOKE ASSEMBLY


    1. A001UVNC01
      *1 Starter Yoke Assembly
      *a Starter Water Drain Hose

      Check the starter water drain hose for damage or clogs.

      If there is damage or clogs, replace the starter yoke assembly.