STARTER(w/ Stop And Start System) INSPECTION

CAUTION / NOTICE / HINT

Tech Tips

When replacing the starter assembly, it is necessary to replace the ST NO. 1 relay and ST NO. 2 relay as well.

PROCEDURE


  1. INSPECT STARTER ASSEMBLY

    CAUTION:

    B006A0H

    • Do not use a thin cable to perform the inspection.

    • If a thin cable is used, the large electric current passing through the cable could cause it to overheat and catch fire, possibly resulting in injuries.

    Note

    Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.


    1. Perform a no-load performance test.


      1. B006DCRC01
        *a Starter Body
        B006AHR Moves Outward

        Connect the positive (+) lead to terminal SL1.

      2. Connect the negative (-) lead to the starter body and check that the clutch 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.

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

      3. B006AO4C01
        *a Starter Body

        With the clutch pinion gear in the outward position, disconnect the negative (-) lead and check that the clutch pinion gear returns inward.

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

      4. B006DOEC01
        *a Starter Body

        Connect the positive (+) lead to terminal SL2 of the connector and the negative (-) lead to the starter body. Check that a clicking sound is heard from the magnet switch.

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

      5. Hold the starter assembly in a vise between aluminum plates.

        Note

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

      6. Connect the battery and an ammeter (AC/DC 400A probe) to the starter assembly as shown in the illustration.

        B006E07C01
        *a Starter Body *b Terminal 30
        *c AC/DC 400 A Probe - -

      7. Connect terminal SL2 and measure the current after the ammeter (AC/DC 400A probe) reading has stabilized.

        Standard current
        130 A or less at 11.5 V

        If the starter assembly does not operate when terminal SL2 is connected, replace the repair service starter kit.

  2. INSPECT REPAIR SERVICE STARTER KIT

    B006A5W

    1. Check the plunger.


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

        Note


        • To avoid damaging the inside of the magnet switch, do not release the plunger quickly.

        • Do not drop the plunger.

        If the plunger does not operate as specified, replace the repair service starter kit.

    2. B006BSTC05
      *a Magnet Switch Body

      Check the repair service starter kit resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal SL1 - Magnet switch body Always Below 1 Ω
        Terminal SL2 - Magnet switch body Below 2 Ω

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

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. B006GK0C04
      *a Length

      Check the brush length.


      1. Using a vernier caliper, measure the brush length.

        Standard length
        14.4 mm (convex part) (0.567 in.)
        Minimum length
        9 mm (convex part) (0.354 in.)

        If the length is less than the minimum, replace the starter brush holder assembly.

    2. B006BKCN21

      Check the starter brush holder assembly resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition

        A - B

        A - C

        B - D

        C - D

        		 Always 10 kΩ or higher

        A - D

        B - C

        		 Below 1 Ω

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

    3. Check the brush spring load.


      1. B006GN2C06
        *a Brush
        *b Brush Spring

        Take a pull scale reading the instant the brush spring separates from the brush.

        Standard spring load
        22.3 to 27.3 N (2 to 3 kgf, 5.0 to 6.1 lbf)
        Minimum spring load
        13.8 N (1 kgf, 3.1 lbf)

        If the spring load is less than the minimum, replace the starter brush holder assembly.

  4. INSPECT STARTER ARMATURE ASSEMBLY


    1. B006BADC02
      *a Segment

      Check the commutator for an open circuit.


      1. 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. B006FZSC02
      *a Segment
      *b Coil Core

      Check the commutator for a short circuit.


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

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

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

    3. Check the commutator appearance.

      If the surface is dirty or burnt, replace the starter armature assembly.

    4. B006D1Y

      Check the commutator for runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the runout.

        Maximum runout
        0.05 mm (0.00197 in.)

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

    5. B006C9A

      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.

    6. B006D4Z

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard undercut depth (convex part)
      0.7 mm (0.0276 in.)
      Minimum undercut depth (convex part)
      0.4 mm (0.0157 in.)

      If the undercut depth is less than the minimum, replace the starter armature assembly.

  5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

    B006B3PC03
    *a Free
    *b Lock

    1. Check the clutch pinion gear.


      1. While holding the starter center bearing clutch sub-assembly, 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 does not operate as specified, replace the starter center bearing clutch sub-assembly.