STARTER INSPECTION


  1. INSPECT STARTER ASSEMBLY

    Note

    Perform each of the following tests within 3 to 5 seconds.


    1. A005UDOE01
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C

      Perform a pull-in test.


      1. 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, replace the magnet starter switch assembly.

    2. A005SQ0E01
      Text in Illustration
      *1 Terminal C

      Perform a holding test.


      1. 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. A005VQ9E01
      Text in Illustration
      *1 Starter Body

      Inspect the clutch pinion gear return.


      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 magnet starter switch assembly.

    4. Perform an operation test without load.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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

      3. A005VXXE01
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

        Connect the battery and 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 MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A005TSU

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

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

    2. A005WDIE01
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

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


      1. 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. A005TMAE04
      Text in Illustration
      *1 Terminal 50

      Check if the hold-in coil has an open circuit.


      1. 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.

  3. INSPECT STARTER ARMATURE ASSEMBLY


    1. A005TLEE05
      Text in Illustration
      *1 Segment

      Measure the resistance.


      1. 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. A005VEUE08
        Text in Illustration
        *1 Segment
        *2 Coil Core

        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.

    2. Check the appearance.

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

    3. A005RYY

      Check the commutator circle runout.


      1. Place the armature on V-blocks.

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

        Standard runout
        0.02 mm (0.000787 in.)
        Maximum runout
        0.05 mm (0.00197 in.)

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

    4. A005S8D

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.14 in.)
      Minimum diameter
      28.0 mm (1.10 in.)

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

    5. A005U0Y

      Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

      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, increase the depth using a hacksaw blade.

  4. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A005VE5

      Using a vernier caliper, measure the brush length.

      Standard length
      14.4 mm (0.567 in.)
      Minimum length
      9.0 mm (0.354 in.)

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

    2. A005SXPE01

      Check the brush holder.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        A - B Always 10 kΩ or higher
        A - C Always 10 kΩ or higher
        A - D Always Below 1 Ω
        B - C Always Below 1 Ω
        B - D Always 10 kΩ or higher
        C - D Always 10 kΩ or higher

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

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planet gears, and the internal gear and pinion gear of the starter center bearing clutch sub-assembly for wear or damage.

      If any of the gears is damaged, replace the gear or center bearing clutch sub-assembly.

    2. A005TR7E02
      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 the result is not as specified, replace the clutch sub-assembly.