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 become hot and cause injury.

    Note

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


    1. Perform pull-in/holding test.


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

      2. A01FIK5E07
        Text in Illustration
        *1 Terminal 50
        *2 Terminal C
        A01FGIV Moves Outward

        Connect the battery to the starter as shown in the illustration. Then check that the clutch pinion gear moves outward.

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

      3. A01FETIE07
        Text in Illustration
        *1 Terminal C
        A01FGIV Disconnect

        Disconnect the negative (-) lead from terminal C under the conditions of the pull-in test. Check that the pinion gear remains out.

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

      4. A01FDHPE06

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

        Text in Illustration
        A01FGIV Disconnect
        A01FJ4N Returns Inward

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

    2. Perform operation test without load.


      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. Mount the starter in a vise.

      3. A01FHC5E07
        Text in Illustration
        *1 Terminal 30
        *2 Terminal 50

        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 outward.

        Standard current
        90 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. Inspect the commutator for an open circuit.


      1. A01FIG7E16
        Text in Illustration
        *1 Segment

        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.

    2. Inspect the commutator for a short circuit.


      1. A01FDXXE17
        Text in Illustration
        *1 Coil Core
        *2 Segment

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Coil core Always 10 kΩ or higher

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

    3. Check the commutator surface for dirt or burns.

      If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.

    4. A01FIFEE07
      Text in Illustration
      *1 Depth

      Using a vernier caliper, measure the depth indicated in the illustration.

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

      If the depth is more than the maximum, replace the armature assembly.

  3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01FF7IE05
      Text in Illustration
      *1 Length

      Using a vernier caliper, measure the brush length.

      Standard length
      9.0 mm (0.354 in.)
      Minimum length
      4.0 mm (0.158 in.)

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

    2. Check the resistance.


      1. A01FE6B

        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, replace the starter commutator end frame assembly.

  4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

      If damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

    2. A01FECW

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

      Text in Illustration
      A01FGIV Free
      A01FJ4N Lock

      If necessary, replace the center bearing clutch sub-assembly.

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. A01FEJDE01

      Check the operation.


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

        If necessary, replace the repair service starter kit.

    2. Check the resistance.


      1. A01FDBLE06
        Text in Illustration
        *1 Terminal C
        *2 Terminal 50

        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

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

      2. A01FG3EE10
        Text in Illustration
        *1 Switch Body
        *2 Terminal 50

        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

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