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STARTER INSPECTION

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  1. Click here

    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. A01558F

      Perform the operation test without load.


      1. Grip the starter in a vise.

      2. Connect the battery and an ammeter to the starter with terminal 30 disconnected.

        Note:

        Do not connect terminal 30 to the battery in this step.

      3. Connect terminal 30 to the battery and check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

        Standard current
        200 A or less at 11 V

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

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    INSPECT STARTER ARMATURE ASSEMBLY


    1. A0159RO

      Inspect 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
        Commutator Always Below 1 Ω

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

    2. A015AWC

      Inspect 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
        Commutator - Armature coil core Always 10 kΩ or higher

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

    3. A01561X

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      36.0 mm (1.42 in.)
      Minimum diameter
      35.0 mm (1.38 in.)

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

    4. A015BU6

      Measure the undercut depth of the commutator.

      Standard undercut depth
      0.7 mm (0.0276 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

      If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.

    5. A015DWP

      Check that the bearing rotates smoothly.

      If necessary, replace the starter armature assembly.

    6. A015804

      Inspect the commutator circle runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circle runout.

        Maximum circle runout
        0.05 mm (0.00197 in.)

        If the runout is more than the maximum, correct it with sandpaper (#400) or replace the armature assembly.

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    INSPECT STARTER YOKE ASSEMBLY


    1. A015CE3

      Inspect the field 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 C plate - Brushes Always Below 1 Ω

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

    2. A015BQ5

      Inspect if the field coil is grounded.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Brushes - Starter yoke body Always 10 kΩ or higher

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

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    INSPECT STARTER BRUSH


    1. A0159RTE02

      Using a vernier caliper, measure the brush length.

      Standard length
      21.0 mm (0.827 in.)
      Minimum length
      12.0 mm (0.472 in.)

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

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    INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A0157XFE09

      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 brush holder assembly.

    2. A015B5UE07

      Inspect the load of the brush spring.


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

        Standard spring installed load
        36 N (3.6 kgf, 8.0 lbf)
        Minimum spring installed load
        12 N (1.2 kgf, 2.7 lbf)

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

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    INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. Check the starter clutch operation.


      1. Hold the clutch and bearing with one hand and turn the shaft with the other. Check that the inner sleeve turns easily in the "free" direction but cannot turn in the "lock" direction as shown in the illustration.

        If the starter clutch sub-assembly does not operate as specified, replace the starter clutch sub-assembly.

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    INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A015DCXE01

      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 0.3 Ω

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

    2. A0157ADE01

      Check the hold-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 - Housing Body Always Below 0.8 Ω

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