STARTER INSPECTION

PROCEDURE


  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 become hot and cause injury.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a pull-in test.


      1. B0077I2

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

      2. B0075LEC01
        *a Starter Body
        *b Terminal 50
        *c Terminal C
        B0073AQ Moves Outward

        Connect a battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.

        If the clutch pinion gear does not move outward, replace the repair service starter kit.

    2. B0072SVC03
      *a Terminal C
      B0073AQ Disconnect

      Perform a hold-in test.


      1. While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

        If the clutch pinion gear returns inward, replace the repair service starter kit.

    3. B0077RIC02
      B0073AQ Disconnect
      B0077IM Returns Inward

      Perform a clutch pinion gear return test.


      1. 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, replace the repair service starter kit.

    4. Perform a no-load performance test.


      1. B0077I2

        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. Hold the starter assembly in a vise between aluminum plates.

        Note

        Ensure that the starter assembly is secured in the vise to prevent it from falling out.

      3. B0076J1C01
        *a Terminal 30
        *b Terminal 50
        *c AC/DC 400A Probe
        B0073AQ Rotates

        Connect the battery and an AC/DC 400A probe to the starter assembly as shown in the illustration.

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter operates smoothly and steadily while the pinion gear is moving outward.

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

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive terminal - Terminal 30 - Terminal 50 11.5 V 90 A or less

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

  2. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If there is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator appearance.

      If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe.

    2. B0076PMC03
      *a Segment

      Check the commutator for an open circuit.


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

        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. B0073MFC04
      *a Segment
      *b Armature Coil Core

      Check the commutator for a short circuit.


      1. Measure the resistance between the commutator and armature coil core.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Armature Coil core Always 10 kΩ or higher

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

    4. B007657C02
      *a Length

      Using a vernier caliper, measure the commutator length.

      Standard Length
      3.1 mm (0.122 in.)
      Maximum Length
      3.8 mm (0.150 in.)

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

  3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B00778KC01
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard Length
      9.0 mm (0.354 in.)
      Minimum Length
      4.0 mm (0.157 in.)

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

    2. B0074TVC01
      *a Positive (+) Brush
      *b Negative (-) Brush

      Check the brush insulation.


      1. Measure the resistance between the positive (+) and negative (-) brushes.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush - Negative (-) brush Always 10 kΩ or higher

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

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

      If damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

    2. B00765NC02
      *a Free
      *b Lock

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

      If necessary, replace the starter drive housing assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. B0077M7

      Check the plunger.


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

        If necessary, replace the repair service starter kit.

    2. B0074FVC03
      *a Terminal C
      *b Terminal 50

      Check the pull-in coil for an open circuit.


      1. Measure the resistance between terminals 50 and C.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Terminal C Always Below 1 Ω

        If the result is not as specified, replace the repair service starter kit.

    3. B00764OC03
      *a Magnet Switch Body
      *b Terminal 50

      Check the hold-in coil for an open circuit.


      1. Measure the resistance between terminal 50 and the magnet switch body.

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

        If the result is not as specified, replace the repair service starter kit.