STARTER (for 1.6 kW Type) 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. Disconnect the lead wire from terminal C.

      2. A01EY97E03
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C
        *3 Body

        Connect the battery to the magnet starter 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. A01EX7AE03
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C
      *3 Body

      Perform the holding test.


      1. Maintain the battery connections of the pull-in test above, but 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. A01ETFME02
      Text in Illustration
      *1 Terminal 50
      *2 Terminal C
      *3 Body

      Check the clutch pinion gear return.


      1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.

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

    4. A01EV1FE03
      Text in Illustration
      *1 Terminal 30
      *2 Terminal 50

      Perform a no-load performance test.


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

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

      2. Clamp the starter in a vise.

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

      4. Check that the starter 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, replace the starter assembly.

  2. INSPECT STARTER CLUTCH


    1. A01EZ2BE03
      Text in Illustration
      *a Lock
      *b Free

      Check the starter clutch.


      1. 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.

  3. INSPECT MAGNET STARER SWITCH ASSEMBLY


    1. A01EYAV

      Inspect the plunger.


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

        If necessary, replace the magnet starter switch assembly.

    2. A01EY5QE07

      Inspect the pull-in coil.


      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
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C

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

    3. A01EVE4E09

      Inspect the holding coil.


      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
        Text in Illustration
        *1 Terminal 50
        *2 Body

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

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. Inspect the commutator for an open circuit.


      1. A01ETOSE21

        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
        Text in Illustration
        *1 Segment

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

    2. Inspect the commutator for a short circuit.


      1. A01ETDVE17

        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
        Text in Illustration
        *1 Commutator
        *2 Armature coil core

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

    3. Check the surface of the commutator for dirt and burns.

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

    4. A01EUDFE03
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the commutator length.

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

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

  5. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01EV3LE03
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the brush length.

      Standard length
      4.0 to 9.0 mm (0.158 to 0.359 in.)

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

    2. A01EUYE

      Inspect the insulation.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush - Negative (-) brush Always 10 kΩ or higher

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