STARTER INSPECTION


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

      2. A01G46YE02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

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

        If the clutch pinion gear does not extend, replace the repair service starter kit.

    2. A01G8BSE15
      Text in Illustration
      *1 Terminal C
      *a Disconnect

      Perform a hold-in test.


      1. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

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

    3. A01G641E10
      Text in Illustration
      *a Disconnect

      Perform a clutch pinion gear return test.


      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 inward, replace the repair service starter kit.

    4. Perform a no-load performance test.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Clamp the starter assembly in a vise.

        Note

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

      3. A01G4EDE08
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

        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 rotates smoothly and steadily while the 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, repair or replace the starter assembly.

  2. INSPECT REPAIR SERVICE STARTER KIT


    1. A01G8VS

      Check the plunger.


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

        If necessary, replace the repair service starter kit.

    2. A01G7V0E17
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

      Check if the pull-in coil has an open circuit.


      1. Measure the resistance between terminals 50 and C.

        Standard resistance
        Below 1 Ω

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

    3. A01G4CLE14
      Text in Illustration
      *1 Terminal 50
      *2 Switch Body

      Check if the hold-in coil has an open circuit.


      1. Measure the resistance between terminal 50 and the switch body.

        Standard resistance
        Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If these is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator for contamination and burns on its surface.

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

    2. A01G9UHE15
      Text in Illustration
      *1 Segment

      Check if the commutator has an open circuit.


      1. Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1 Ω

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

    3. A01G70IE10
      Text in Illustration
      *1 Commutator
      *2 Armature Coil Core

      Check if the commutator is grounded.


      1. Measure the resistance between the commutator and armature coil core.

        Standard resistance
        10 kΩ or higher

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

    4. A01G91ME22
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the commutator length.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

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

  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01G4OGE19
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard length
      9.0 mm (0.354 in.)
      Minimum length
      4.0 mm (0.157 in.)

      If the length is less than the minimum, replace the starter commutator end frame assembly.

    2. A01G5C5E14

      Check the brush insulation.


      1. Measure the resistance between the positive (+) and negative (-) brushes.

        Standard resistance
        10 kΩ or higher

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

  5. INSPECT STARTER CLUTCH


    1. A01G6FXE13
      Text in Illustration
      *a Lock
      *b Free

      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 starter drive housing assembly.