STARTER(for 2.0 kW Type) INSPECTION

PROCEDURE


  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

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


    1. Perform a pull-in test.


      1. A005JZX

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

      2. A005LO9E02
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50
        *3 Starter 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. A005JS5E02
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50
      *3 Starter 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. A005GLTE02
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50
      *3 Starter 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. A005JZX

      Perform a no-load performance test.


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

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

      2. Hold the starter assembly in a vise between aluminum plates.

        Note

        Do not overtighten the vise.

      3. A005LWAE02
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50
        *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 150 A

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A005HFB

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

        If necessary, replace the magnet starter switch assembly.

    2. A005L8BE02
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C

      Check the pull-in coil for 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. A005I97E03
      Text in Illustration
      *1 Terminal 50
      *2 Switch Body

      Check the holding coil for 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. A005K1UE10
      Text in Illustration
      *1 Segment

      Check the commutator.


      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. A005IS2E14
      Text in Illustration
      *1 Armature Coil Core
      *2 Commutator

      Check the commutator.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Commutator - Armature coil core Always 10 kΩ 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. A005GOZE02
      Text in Illustration
      *1 Armature Shaft

      Check the commutator for circle runout.


      1. Place the armature shaft 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. A005L4K

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      29.0 mm (1.142 in.) (At convex part)
      Minimum diameter
      28.0 mm (1.102 in.) (At convex part)

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

    6. A005JNV

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

      Standard undercut depth
      0.4 mm (0.0158 in.) (At convex part)
      Minimum undercut depth
      0.2 mm (0.00787 in.) (At convex part)

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

  4. INSPECT BRUSH


    1. A005M4H

      Using a vernier caliper, measure the brush length.

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

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Check the brush spring load.


      1. A005MG4E14
        Text in Illustration
        *1 Brush
        *2 Brush Spring

        Take a pull scale reading immediately after the brush spring separates from the brush.

        Standard Spring Load
        22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)
        Minimum Spring Load
        13.8 N (1.41 kgf, 3.1 lbf)

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

    2. Inspect the insulation.


      1. A005K4UE01

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

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

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage.

      If any planetary gear is damaged, replace the planetary gear.

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

    2. A005GN6E04
      Text in Illustration
      *1 Free
      *2 Lock

      Check the movement of the clutch pinion gear.


      1. Hold the starter clutch, rotate the clutch pinion gear clockwise, and check that it turns freely.

      2. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

        If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.