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

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

    1. Perform a pull-in test.

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

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

        A011V0YE02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

        If the clutch pinion gear does not move, replace the magnetic switch assembly.

    2. Perform a hold-in test.

      A011T6TE15

      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.

        Text in Illustration
        *1 Terminal C
        *a Disconnect

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

    3. Perform a clutch pinion gear return test.

      A011SP7E09

      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.

        If the clutch pinion gear does not return, replace the magnetic switch assembly.

        Text in Illustration
        *a Disconnect

    4. Perform a no-load performance test.

      A011UCZE08
      Text in Illustration
      *1 Terminal 30
      *2 Terminal 50

      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 in a vise.

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

      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. Check the plunger.

      A011RSX

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

        If necessary, replace the repair service starter kit.

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

      A011SUEE17
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

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

      A011TE3E14
      Text in Illustration
      *1 Terminal 50
      *2 Body

      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. Check if the commutator has an open circuit.

      A011ULCE15
      Text in Illustration
      *1 Segment

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

        Standard resistance
        Below 1 Ω

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

    3. Check if the commutator is grounded.

      A011T76E10
      Text in Illustration
      *1 Commutator
      *2 Coil Core

      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 armature assembly.

    4. Using a vernier caliper, measure the commutator length.

      A011STRE22
      Text in Illustration
      *a Length
      Standard length
      3.1 to 3.8 mm (0.122 to 0.149 in.)
      Maximum length
      3.8 mm (0.149 in.)

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

  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

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

      A011T3HE17
      Text in Illustration
      *a Length
      Standard length
      4.0 to 9.0 mm (0.158 to 0.354 in.)
      Minimum length
      4.0 mm (0.158 in.)

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

    2. Check the brush insulation.

      A011U9GE14

      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 end frame assembly.

  5. INSPECT STARTER CLUTCH

    1. 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.

      A011SXVE13
      Text in Illustration
      *a Lock
      *b Free

      If necessary, replace the starter drive housing assembly.