STARTER (for 2.7 kW Type) INSPECTION


  1. INSPECT STARTER

    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

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


    1. Mount the starter in a vise between aluminum plates.

    2. Perform a pull-in test.


      1. A00JZZ5E02
        Text in Illustration
        *1 Terminal C

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

      2. A00JYWOE02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

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

        If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    3. Perform a holding test.


      1. A00JVBWE02
        Text in Illustration
        *1 Terminal C

        When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.

        If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    4. Inspect the clutch pinion gear return.


      1. A00JXRU

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

    5. Perform an operation test without load.


      1. A00JX8QE02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30

        Connect the lead wire to terminal C with the nut.

        Torque:
        24 N*m  { 245 kgf*cm, 18 ft.*lbf }

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.

        Standard current
        180 A or less at 11.5 V

        If the result is not as specified, inspect the starter assembly

        Tech Tips

        Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A00K0QXE02
      Text in Illustration
      *1 Terminal 50
      *2 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.

    2. A00JVBGE02
      Text in Illustration
      *1 Terminal 50

      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 - Starter switch body Always Below 2 Ω

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

  3. INSPECT BRUSH

    A00K068E09

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

      Standard length
      20.5 mm (0.807 in.)
      Minimum length
      11.0 mm (0.433 in.)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A00K05YE02

      Inspect the brush insulation.


      1. 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 starter brush holder assembly.

    2. A00JUQ1E02

      Take the pull scale reading the instant the brush spring separates from the brush.

      Standard spring installed load
      34 to 42 N (3.5 to 4.3 kgf, 7.7 to 9.5 lbf)
      Minimum spring installed load
      19 N (1.9 kgf, 4.2 lbf)

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

  5. INSPECT STARTER YOKE ASSEMBLY


    1. A00JTMS

      Inspect the field coil for open circuit.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal C - Brush Always Below 1 Ω

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

    2. A00JVC7

      Inspect the field coil for a short circuit to ground.


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

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

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

  6. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator for dirt and/or burns on the surface.

      If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe. If necessary, replace the starter armature assembly.

    2. A00K0QJE08
      Text in Illustration
      *1 Segment

      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
        Segment - Segment Always Below 1 Ω

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

    3. A00JUGOE09
      Text in Illustration
      *1 Segment
      *2 Coil Core

      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
        Segment - Coil core Always 10 kΩ or higher

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

    4. A00JVRU

      Inspect the commutator for circle runout.


      1. Place the armature on V-blocks.

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

        Maximum circle runout
        0.05 mm (0.00197 in.)

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

    5. A00JZWB

      Using a vernier caliper, measure the commutator diameter.

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

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

    6. A00JV4T

      Using a vernier caliper, 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, replace the starter armature assembly.

    7. Inspect the bearings.


      1. Check that the bearings rotate smoothly.

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

  7. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A00K0P5

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

      Text in Illustration
      A00JWY4 Free
      A00JYOS Lock

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

    2. Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

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