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. Otherwise, the cable may become hot and cause injury.

    Note

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.


    1. Mount the starter 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. A015ANCE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        Connect the battery to the starter as shown in the illustration. Then check that the clutch pinion gear moves outward.

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

    3. Perform a holding test.


      1. A015810E02
        Text in Illustration
        *1 Terminal C

        Disconnect the negative (-) terminal 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 moves inward, replace the magnet starter switch assembly.

    4. Inspect the clutch pinion gear return.


      1. A0156D3

        Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear moves inward.

        If the clutch pinion gear does not move inward, 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:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. A0158GBE02
        Text in Illustration
        *1 Terminal 30
        *2 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 moving outward. Then measure the current.

        Standard current
        150 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. 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.

    2. Inspect the commutator for an open circuit.


      1. A0158A8E02
        Text in Illustration
        *1 Segment

        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. Inspect the commutator for a short circuit.


      1. A0159T0E02
        Text in Illustration
        *1 Coil Core
        *2 Segment

        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.

    4. A015DKX

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.14 in.)
      Minimum diameter
      28.0 mm (1.10 in.)

      Tech Tips

      Be sure to measure the commutator diameter at the ridges.

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

    5. Check the commutator circle runout.


      1. Place the armature shaft on V-blocks.

      2. A015ASZ

        Using a dial indicator, measure the circle runout.

        Maximum commutator runout
        0.05 mm (0.00197 in.)

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

    6. A015D7AE01

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

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

      Tech Tips

      Be sure to measure the commutator undercut depth at a cutout.

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A0155LN

      Using a vernier caliper, measure the brush length.

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

      Tech Tips

      Be sure to measure the brush lengths at the protrusions.

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

    2. Inspect the load of the brush spring.


      1. A0159KGE02
        Text in Illustration
        *1 Brush
        *2 Brush Spring

        Take a pull scale reading immediately after the brush spring separates from the brush.

        Standard spring load
        22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf)
        Minimum spring load
        14 N (1 kgf, 3.1 lbf)

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

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth of the planetary gears and starter center bearing clutch for wear or damage.

      If any planetary gear is damaged, replace the planetary gears. If any teeth of the starter center bearing clutch are damaged, replace the starter center bearing clutch sub-assembly.

    2. A015AYJ

      Check the movement of the clutch pinion gear.


      1. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

        Text in Illustration
        A015DIT Free
        A015CC1 Lock

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Inspect the pull-in coil.


      1. A0159JXE03
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        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.

    2. Inspect the holding coil.


      1. A015C2NE03
        Text in Illustration
        *1 Terminal 50
        *2 Switch Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Switch body Always Below 2 Ω

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