СТАРТЕР (для моделей мощностью 0,8 кВт) ПРОВЕРКА


  1. INSPECT STARTER ASSEMBLY

    Note

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


    1. A0119NF

      Perform a pull-in test.


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

      2. A0117NRE01
        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. A011AJ2E01
      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. A0118I0E01
      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. A0119NF

      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. A011BJAE01
        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. A0119A5

        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. A011A3R

        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. A011BY0

        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. A0118AWE02
      Text in Illustration
      *1 Ohmmeter
      *2 Brush Lead
      *3 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. A01191CE02
      Text in Illustration
      *1 Ohmmeter
      *2 Brush Lead
      *3 Body

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

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

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

  4. INSPECT STARTER BRUSH


    1. A011B4S

      Using a vernier caliper, measure the brush length.

      Standard length
      10.0 mm (0.394 in.)
      Minimum length
      6.0 mm (0.236 in.)

      If the length is less than the minimum, replace the starter brush.

  5. REPLACE STARTER BRUSH


    1. A011759E02
      Text in Illustration
      *1 Cut

      Cut the brush lead wire on the terminal side.

    2. A01193U

      Smooth the brush lead wire using a file.

      Note

      Only a small area can be filed, do not damage the yoke.

    3. A011BO4E02
      Text in Illustration
      *1 Brush
      *2 Plate
      *3 Weld Side
      *4 Press

      Using pliers, pinch the plate of the brush (service part) on the weld side of the terminal lead wire and apply force.

    4. A011BOF

      Apply solder to the contact surface.

      Tech Tips


      • Heat the contact surface well. Apply a sufficient amount of solder to the inside of the plate while paying attention not to apply it to the lead wire.

      • Do not apply solder to the field coil.

  6. INSPECT STARTER BRUSH SPRING


    1. Check visually.

      Specified Condition
      No rust, abrasion or damage.

    2. Using a vernier caliper, measure the brush spring length.

      Standard length
      21.5 mm (0.846 in.)

  7. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A011BT3E02
      Text in Illustration
      *1 Free
      *2 Look

      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.

  8. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A0118IUE02
        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. A011AOAE19
        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. A011AOAE20
        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.