STARTER INSPECTION
PROCEDURE
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INSPECT STARTER ASSEMBLY
CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may became hot and cause injury.
Note
Perform each of the following tests within 3 to 5 seconds.
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Perform a no-load performance test.
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Connect the positive (+) lead to the terminal SL1.
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Text in Illustration *1 Starter Body Connect the negative (-) lead to the starter body and check that the pinion gear moves outward.
Note
If the positive and negative leads are connected incorrectly, the IC inside of the starter inrush current reduction relay will be damaged. Be sure to connect them correctly.
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Text in Illustration *1 Starter Body With the pinion gear in the pulled-out position, disconnect the negative (-) lead and check that the pinion gear moves in.
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Text in Illustration *1 Starter Body Connect the positive (+) lead to the SL2 terminal of the connector and the negative (-) lead to the starter body. Check that a clicking sound is heard from the starter motor.
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Clamp the starter assembly in a vise between aluminum plates.
Note
Ensure that the starter is secured in the vise to prevent it from falling out.
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Connect the battery and an ammeter to the starter assembly as shown in the illustration.
Text in Illustration *1 Starter Body *2 Terminal 30 *3 Ammeter - - -
Connect the SL2 terminal and take measurements when the current variations on the ammeter are small.
Standard Current Tester Connection Condition Specified Condition Battery positive terminal - Terminal 30 - Terminal SL2 11.5 V Below 130 A Tech Tips
If the starter does not operate when connecting the SL2 terminal, perform steps 8 through 11.
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Text in Illustration *1 Terminal C *2 Terminal M Disconnect the connector.
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Remove the 2 nuts and disconnect the wire harness leads from terminals C and M.
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Connect the M wire harness lead to terminal C, and then install and tighten the nut.
- Torque:
- 9.0 N*m { 92 kgf*cm, 80 in.*lbf }
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Connect the battery and an ammeter to the starter assembly as shown in the illustration.
Text in Illustration *1 Starter Body *2 Terminal 30 *3 Ammeter - - Tech Tips
If the starter motor assembly does not operate, replace the magnet starter switch assembly.
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INSPECT MAGNET STARTER SWITCH ASSEMBLY
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Check the plunger.
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Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the magnet starter switch assembly.
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Text in Illustration *1 Switch Body Check the pull-in coil for an open circuit.
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Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Terminal SL1 - Body ground Always Below 1 Ω Terminal SL2 - Body ground Always Below 2 Ω If the result is not as specified, replace the magnet starter switch assembly.
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INSPECT STARTER ARMATURE ASSEMBLY
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Text in Illustration *1 Commutator *2 Armature Check the commutator.
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Measure the resistance according to the value(s) in the table below.
Standard Resistance Tester Connection Condition Specified Condition Commutator - Armature Always 10 kΩ or higher If the result is not as specified, replace the starter armature assembly.
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Text in Illustration *1 Segment Check the commutator.
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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.
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Check the commutator surface for dirt and burns. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.
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Check the commutator circuit for runout.
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Place the commutator on V-blocks.
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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.
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Using a vernier caliper, measure the commutator diameter.
Standard diameter (Convex part) 29 mm (1.14 in.) Minimum diameter (Convex part) 28 mm (1.10 in.) If the diameter is less than the minimum, replace the starter armature assembly.
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Check that the undercut portion is clean and free of foreign matter. Smooth out the edges.
Standard undercut depth (Convex part) 0.4 mm (0.0158 in.) Minimum undercut depth (Convex part) 0.2 mm (0.00787 in.) If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.
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INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
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Check the gear teeth of the planetary gear and starter center bearing clutch sub-assembly for wear or damage.
If any planetary gear is damaged, replace the planetary gear assembly.
If any gear of the starter center bearing clutch sub-assembly is damaged, replace the starter center bearing clutch sub-assembly.
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Text in Illustration *a Free *b Lock Check the movement of the clutch pinion gear.
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Hold the starter clutch, 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.
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.
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INSPECT STARTER BRUSH HOLDER ASSEMBLY
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Remove the claw of the spring, then remove the 4 brushes.
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Text in Illustration *a Length Using a vernier caliper, measure the brush length.
Standard length 14.4 mm (0.567 in.) Minimum length (Convex part) 9.0 mm (0.354 in.) If the length is less than the minimum, replace the starter brush holder assembly.
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Check the brush holder.
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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.
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