STARTER (for 2.0 kW Type) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, the cable may become hot and cause injury.

    Note

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


    1. Mount the starter assembly in a vise between aluminum plates.

    2. Perform a pull-in test.


      1. Detach the wire harness clamp, remove the nut and disconnect the lead wire from terminal C.

      2. A01J5GUE01
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50
        A01J5O1 Moves outward

        Connect the battery to the starter assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

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

    3. Perform a holding test.


      1. A01J772E01
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50
        A01J5O1 Disconnect

        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 out.

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

    4. Inspect clutch pinion gear return.


      1. A01J463

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

        Text in Illustration
        A01J5O1 Disconnect
        A01J67K Returns inward

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

    5. Perform an operation test without load.


      1. Attach the wire harness clamp and connect the lead wire to terminal C with the nut.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      2. A01J7CJE01
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30

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

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

        Standard current
        100 A or less at 11.5 V

  2. 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.

      If necessary, replace the starter armature assembly.

    2. Check the resistance.


      1. A01J7IQE06
        Text in Illustration
        *1 Segment

        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. A01J30EE06
        Text in Illustration
        *1 Coil Core
        *2 Segment

        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

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

    3. Check the commutator circle runout.


      1. A01J6AU

        Place the commutator on V-blocks.

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

        Maximum runout
        0.05 mm (0.00197 in.)
    4. A01J3HPE01

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.39 in.)
      Minimum diameter
      34.0 mm (1.34 in.)

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

    5. A01J613E01

      Measure the undercut depth of the commutator.

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

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

      If necessary, replace the starter armature assembly.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. Check the resistance.


      1. A01J5N5E02

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead wire - Field coil brush lead Always Below 1 Ω

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

      2. A01J4UVE01

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Shunt coil terminal - Shunt coil terminal 20°C (68°F) 1.5 to 1.9 Ω

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

    2. Check the brush length.


      1. A01J6G4E01
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length.

        Standard length
        15.0 mm (0.591 in.)
        Minimum length
        9.0 mm (0.354 in.)

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

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the resistance.


      1. A01J47EE02

        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. A01J4ZZ

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

        Standard spring load
        22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)
        Minimum spring load
        12 N(1 kgf, 2.8 lbf)

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

      2. A01J4POE01
        Text in Illustration
        *a Length

        Using a vernier caliper, measure the brush length

        Standard length
        15.0 mm (0.591 in.)
        Minimum length
        9.0 mm (0.354 in.)

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

  5. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. Check the clutch pinion gear teeth for wear or damage.

      If the clutch pinion gear teeth are damaged, replace the starter clutch sub-assembly and also inspect the flywheel ring gear for wear or damage.

    2. A01J3CH

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

      Text in Illustration
      A01J5O1 Free
      A01J67K Lock

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

  6. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the resistance.


      1. A01J3S6E03
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        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.

      2. A01J59UE03
        Text in Illustration
        *1 Terminal 50

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

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

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