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. 

         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. 

         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. 

      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. 

      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. 

      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. 

      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. 

      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. 

      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.

      

      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. 

      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. 

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

      If necessary replace the repair service starter kit.

   2. 

      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.