STARTER(w/ Stop And Start System) INSPECTION

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    Note

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


    1. Perform a no-load performance test.


      1. A005GU3

        Connect the lead wire to the terminal C with the nut. Make sure that the lead is not grounded.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      2. Hold the starter assembly in a vise between aluminum plates.

        Note

        Do not overtighten the vise.

      3. A005JN9E03
        Text in Illustration
        *1 Terminal 50
        *2 Terminal 30
        *3 Body
        *4 Ammeter

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

      4. Check that the starter operates smoothly and steadily.

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

        Standard Current
        Tester Connection Condition Specified Condition
        Battery positive terminal - Terminal 30 11.5 V Below 90 A

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

  2. INSPECT STARTER ARMATURE WITH CLUTCH ASSEMBLY


    1. A005IBNE02
      Text in Illustration
      *1 Commutator

      Inspect the resistance of 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 with clutch assembly.

    2. A005MB0E03
      Text in Illustration
      *1 Armature Coil Core
      *2 Commutator

      Inspect the resistance of the commutator for a short to ground.


      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 with clutch 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. A005GXT

      Check the commutator for circle runout.


      1. 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 with clutch assembly.

    5. A005I4D

      Using a vernier caliper, measure the commutator diameter.

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

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

    6. A005JWY

      Check that the undercut portion is clean and free of foreign matter, with smooth edges.

      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.

    7. A005HZSE05
      Text in Illustration
      *a Free
      *b Lock

      Inspect the clutch.


      1. Rotate the armature counterclockwise and check that it turns freely. Try to rotate the armature clockwise and check that it locks. If necessary, replace the starter armature with clutch assembly.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. Remove the claw of the spring, and then remove the 4 brushes.

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

      A005KNBE06
      Text in Illustration
      *1 Brush *2 Spring
      *a Length - -
      Standard length
      14.4 mm (0.567 in.)
      Minimum length
      9 mm (0.3543 in.)

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

    3. A005JPEE06

      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.

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Inspect the gear teeth on the planetary gear and internal gears for wear and damage.

      If damaged, replace the starter planetary gear or starter center bearing clutch sub-assembly. Also check the starter planetary gear for wear or damage.

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. A005I7P

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

      If necessary replace the repair service starter kit.

    2. A005LE5E27
      Text in Illustration
      *1 Terminal 50
      *2 Body

      Check whether the 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 - Body Always Below 2 Ω

        If the result is not as specified, replace the repair service starter kit.