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СТАРТЕР ПРОВЕРКА

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    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:

    The following tests must each 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. Remove the nut, and then disconnect the lead wire from terminal C.

      2. A00JTUOE01

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

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

        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. A00JW06E01

        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 extended.

        Table 2. Text in Illustration
        *1 Terminal C

        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. A00JXUV

        Disconnect the negative (-) terminal 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. Connect the field coil lead wire to terminal C.

        5.9 N*m 60 kgf*cm 52 in.*lbf
      2. A00K0GZE01

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

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

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

        Specified current
        120 A or less at 11.5 V

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

        Tip:

        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.

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    INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Inspect the pull-in coil.


      1. A00K0PHE02

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal C - Terminal 50 Always Below 1 Ω
        Table 4. Text in Illustration
        *1 Terminal C
        *2 Terminal 50

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

    2. Inspect the holding coil.


      1. A00JX0GE02

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Switch body - Terminal 50 Always Below 2 Ω
        Table 5. Text in Illustration
        *1 Switch Body
        *2 Terminal 50

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

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    INSPECT BRUSH


    1. A00JWIIE02

      Using a vernier caliper, measure the brush length.

      Table 6. Text in Illustration
      *1 Length
      *a Brush Holder Side
      *b Starter Yoke Side
      Standard brush length
      16.5 mm (0.650 in.)
      Minimum brush length
      9.0 mm (0.354 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. A00JV71E01

      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. Check the brush spring load.


      1. A00JUQ1E11

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

        Standard spring load
        27 to 32 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)
        Minimum spring load
        18 N (2 kgf, 4.0 lbf)
        Table 7. Text in Illustration
        *1 Brush Spring
        *2 Brush

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

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    INSPECT STARTER YOKE ASSEMBLY


    1. Inspect for an open circuit.


      1. A00K08S

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead wire - Brush Always Below 1 Ω

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

    2. Inspect for a short circuit.


      1. A00JZ6S

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

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

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

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    INSPECT STARTER ARMATURE ASSEMBLY


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

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

    2. Inspect the commutator for an open circuit.


      1. A00JZPHE02

        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
        Table 8. Text in Illustration
        *1 Segment

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

    3. Inspect the commutator for a short circuit.


      1. A00JUCGE02

        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
        Table 9. Text in Illustration
        *1 Segment
        *2 Coil Core

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

    4. Inspect the commutator circle runout.


      1. A00K01IE01

        Place the armature 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 (No. 400) or replace the starter armature assembly.

    5. A00JTMYE01

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.38 in.)
      Minimum diameter
      34.0 mm (1.34 in.)

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

    6. A00JYVOE01

      Measure the undercut depth of the commutator.

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

      If the undercut depth is less than the minimum, correct it with a hacksaw blade.

    7. Inspect the bearings.


      1. Check that the bearing rotates smoothly.

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

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    INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A00K24Y

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

      Table 10. Text in Illustration
      A00JWY4 Free
      A00JYOS Lock

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

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

      If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.