STARTER (for 1.4 kW Type) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    Note

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


    1. Perform pull-in test.


      1. A01J4IVE01

        Remove the nut, and then disconnect the field coil lead wire from terminal C.

      2. 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 outward, replace the magnet starter switch assembly.

    2. Perform holding test.


      1. A01J37NE01

        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 moves inward, replace the magnet starter switch assembly.

    3. Inspect clutch pinion gear return.


      1. A01J3R4E01

        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 magnet starter switch assembly.

    4. Perform operation test without load.


      1. Connect the field coil lead wire to terminal C with the nut.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

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

      3. A01J3UVE01

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

      4. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

        Standard current
        90 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Measure the resistance.


      1. A01J3XAE01

        Measure the resistance between any 2 segments of the commutator.

        Standard resistance
        Below 1 Ω

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

      2. A01J3J3E01

        Measure the resistance between each segment of the commutator and the armature coil core.

        Standard resistance
        10 kΩ or higher

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

    2. A01J6DV

      Inspect circle runout.


      1. Place the armature on V-blocks.

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

        Maximum circle runout
        0.05 mm (0.0020 in.)

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

    3. A01J3EV

      Using a vernier caliper, measure the commutator diameter.

      Standard commutator diameter
      30.0 mm (1.18 in.)
      Minimum commutator diameter
      29.0 mm (1.14 in.)

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

    4. A01J47J

      Measure the undercut depth of the commutator.

      Standard undercut depth
      0.6 mm (0.023 in.)
      Minimum undercut depth
      0.2 mm (0.008 in.)

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

    5. Inspect the armature bearings.


      1. Check that the armature bearings rotate smoothly.

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

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A01J6HJ

      Inspect the field coil for an open circuit.


      1. Measure the resistance between the lead wire and field coil brush lead.

        Standard resistance
        Below 1 Ω

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

    2. A01J4S3

      Inspect the ground.


      1. Measure the resistance between the lead wire and starter yoke body, and between the brushes and starter yoke body.

        Standard resistance
        10 kΩ or higher

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

  4. INSPECT BRUSH


    1. A01J7DV

      Using a vernier caliper, measure the brush length.

      Standard length
      15.5 mm (0.610 in.)
      Minimum length
      8.5 mm (0.335 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01J4H7

      Inspect the brush insulation.


      1. Using an ohmmeter, measure the resistance between the positive and negative brush holders.

        Standard resistance
        10 kΩ or higher

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

    2. A01J7GZ

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

      Standard spring load
      17.6 to 23.5 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf)
      Minimum spring load
      11.8 N (1.2 kgf, 2.7 lbf)

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

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01J3WTE01

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

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

    2. Turn the bearing by hand while applying inward force.

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

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check if the pull-in coil has an open circuit.


      1. A01J6ORE01

        Measure the resistance between terminal 50 and terminal C.

        Standard resistance
        Below 1 Ω

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

    2. Check if the holding coil has an open circuit.


      1. A01J3KI

        Measure the resistance between terminal 50 and the switch body.

        Standard resistance
        Below 2 Ω

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