STARTER INSPECTION


  1. 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

    These tests must be performed within 3 to 5 seconds to avoid burning out the coil.


    1. Perform a pull-in test.


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

      2. A01EX9ZE02
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

        Connect the battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear extends.

        If the clutch pinion gear does not move, replace the magnet starter switch assembly.

    2. Perform a hold-in test.


      1. A01ETEKE11
        Text in Illustration
        *1 Disconnect
        *2 Terminal C

        While maintaining the battery connections of the pull-in test above, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

        If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

    3. Perform a clutch pinion gear return test.


      1. A01EXERE06
        Text in Illustration
        *1 Disconnect

        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 a no-load performance test.


      1. Connect the lead wire to terminal C with the nut. Make sure that the lead wire 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

        Ensure that the starter assembly is secured firmly in the vise to prevent it from falling out.

      3. A01EVCTE08
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

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

        Note

        Do not allow any lead to get caught as the pinion gear operates.

      4. Check that the starter assembly rotates smoothly and steadily while the pinion gear is moving out. Then measure the current.

        Standard current
        90 A or less at 11.5 V

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

  2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. Check the plunger.


      1. A01EXIF

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

        If necessary, replace the magnet starter switch assembly.

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


      1. A01EWPFE17
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        Measure the resistance between terminals 50 and C.

        Standard resistance
        Below 1 Ω

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

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


      1. A01EXM6E14
        Text in Illustration
        *1 Terminal 50
        *2 Magnet Switch Body

        Measure the resistance between terminal 50 and the magnet switch body.

        Standard resistance
        Below 2 Ω

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

  3. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If these is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator for contamination and burns on its surface.

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

    2. Check if the commutator has an open circuit.


      1. A01ETOSE15
        Text in Illustration
        *1 Segment

        Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1 Ω

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

    3. Check if the commutator is grounded.


      1. A01ETDVE10
        Text in Illustration
        *1 Segment
        *2 Armature Coil Core

        Measure the resistance between the commutator and armature coil core.

        Standard resistance
        10 kΩ or higher

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

    4. A01EYBOE22
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the commutator length.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

      If the length is greater than the maximum, replace the starter armature assembly.

  4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01ETVGE19
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard length
      9.0 mm (0.354 in.)
      Minimum length
      4.0 mm (0.157 in.)

      If the length is less than the minimum, replace the starter commutator end frame assembly.

    2. A01ETNRE14

      Check the brush insulation.


      1. Measure the resistance between the positive (+) and negative (-) brushes.

        Standard resistance
        10 kΩ or higher

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

  5. INSPECT STARTER CLUTCH


    1. A01EVUGE13
      Text in Illustration
      *a Lock
      *b Free

      Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.

      If necessary, replace the repair service starter kit.