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

    Perform each of the following tests within 3 to 5 seconds.


    1. Perform a pull-in test.


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

      2. A019OLIE05
        Text in Illustration
        *a Terminal 50
        *b Terminal C

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

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

    2. A019LVUE06
      Text in Illustration
      *a Terminal 50
      *b Terminal C

      Perform a holding test.


      1. 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 magnetic switch assembly.

    3. A019NLPE01
      Text in Illustration
      *a Terminal 50
      *b Terminal C

      Perform a clutch pinion gear return test.


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

        If the clutch pinion gear does not return, replace the magnetic 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 is not grounded.

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

      2. Clamp the starter assembly in a vise.

        Note

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

      3. A019KI6E04
        Text in Illustration
        *a Terminal 50
        *2 Terminal 30

        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 rotates.

      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 MAGNETIC SWITCH ASSEMBLY


    1. A019L5M

      Check the plunger.


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

        If the plunger does not return, replace the magnetic switch assembly.

    2. A019N9ME32
      Text in Illustration
      *a Terminal C
      *b Terminal 50

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


      1. Measure the resistance between terminals 50 and C.

        Standard Resistance
        Below 1 Ω

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

    3. A019P21E25
      Text in Illustration
      *a Terminal 50
      *b Switch Body

      Check if the holding coil has an open circuit.


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

        Standard Resistance
        Below 2 Ω

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

  3. INSPECT 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. A019MEAE05
      Text in Illustration
      *a Segment

      Check if the commutator has an open circuit.


      1. 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. A019O4EE03
      Text in Illustration
      *a Commutator
      *b Coil Core

      Check if the commutator is grounded.


      1. 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. A019M1AE22
      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. A019MLZE17
      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. A019KTQE14

      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. A019JP1E13
      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.