STARTER (for 1.0 kW Type) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    Note

    The following tests must be performed within 5 seconds to prevent the coil from burning out.


    1. A01186K

      Perform a pull-in test.


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

      2. A011BS1E01
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C
        *3 Body

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

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

    2. A011AMPE01
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C
      *3 Body

      Perform a holding test.


      1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.

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

    3. A011AWUE01
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C
      *3 Body

      Inspect the clutch pinion gear return.


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

        If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.

    4. A01186K

      Perform a no-load performance test.


      1. Connect the motor lead wire to terminal C. Make sure that the lead is not grounded.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      2. Clamp the starter in a vise.

        Note

        Do not clamp the vise too tightly.

      3. A011BKZE01
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30
        *3 Body

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

      4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended.

        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 Below 90 A

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Check the commutator.


      1. A0119W5

        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.

    2. Check the commutator.


      1. A011733

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Commutator - Armature core Always 10 MΩ or higher

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

    3. Check the commutator surface for dirt and burns.

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

    4. Check the commutator for circle runout.


      1. A011720

        Place the commutator on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. A01184F

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      28.0 mm (1.10 in.)
      Minimum diameter
      27.0 mm (1.06 in.)

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

    6. A0118QI

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard undercut depth
      0.6 mm (0.0236 in.)
      Minimum undercut depth
      0.2 mm (0.00787 in.)

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

  3. INSPECT FIELD COIL


    1. A0117SSE02
      Text in Illustration
      *1 Brush Lead
      *2 Terminal C

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

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

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

    2. A011B02E02
      Text in Illustration
      *1 Brush Lead
      *2 Body

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

      Standard Resistance
      Tester Connection Condition Specified Condition
      Brush wire - Body Always 10 MΩ or higher

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

  4. INSPECT BRUSH


    1. A0118ZS

      Using a vernier caliper, measure the brush length.

      Standard length
      14.0 mm (0.551 in.)
      Minimum length
      9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A011A5XE01

      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 MΩ or higher

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

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A011BH2E02
      Text in Illustration
      *1 Free
      *2 Lock

      Hold the starter clutch, 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 clutch sub-assembly.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A0118IUE03
        Text in Illustration
        *1 Plunger

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

        If necessary, replace the magnet starter switch assembly.

    2. Check the pull-in coil for an open circuit.


      1. A011AOAE21
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

        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.

    3. Check the hold-in coil for an open circuit.


      1. A011BFVE15
        Text in Illustration
        *1 Terminal 50
        *2 Body

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Body Always Below 2 Ω

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