STARTER(for 1.3 kW Type) INSPECTION

PROCEDURE

1. INSPECT STARTER ASSEMBLY

   CAUTION:

   As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, 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. Mount the starter assembly in a vise between aluminum plates.

   2. Perform a pull-in test.

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

      2. 

         *1	Terminal 50
         *2	Terminal C
         	Moves Outward

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

         If the clutch pinion gear does not move, replace the motor terminal starter kit.

   3. 

      *1	Terminal C
      	Disconnect

      Perform a holding test.

      1. Disconnect the negative (-) lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.

         If the clutch pinion gear moves inward, replace the motor terminal satarter kit.

   4. 

      	Disconnect
      	Returns Inward

      Inspect the clutch pinion gear return.

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

         If the result is not as specified, replace the motor teminal starter kit.

   5. Perform an operation test without load.

      1. Connect the lead wire to terminal C with the nut.

         10 N*m

         102 kgf*cm

         7 ft.*lbf

      2. 

         *1	Terminal 30
         *2	Terminal 50
         	Connect

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

      3. 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, replace the starter assembly.

2. INSPECT STARTER ARMATURE ASSEMBLY

   1. Check the commutator for dirt and/or burns on the surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

      If necessary, replace the starter armature assembly.

   2. 

      *1

      Segment

      Inspect 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.

   3. Inspect the commutator for a short circuit.

      1. 

         *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.

   4. 

      *1

      Length

      Using a vernier caliper, measure the protrusion length.

      Standard length

      3.1 mm (0.122 in.)

      Maximum length

      3.8 mm (0.150 in.)

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

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   1. 

      *1

      Length

      Check the brush length.

      1. 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. 

      Check the resistance.

      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, replace the starter commutator end frame assembly.

4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   1. Check the gear teeth on the planetary gears, and the internal gear and pinion gear of the starter center bearing clutch sub-assembly for wear or damage.

      If any of the gears is damaged, replace the starter center bearing clutch sub-assembly.

   2. Check the starter center bearing clutch pinion gear.

      1. 

         	Free
         	Lock

         Hold the starter center bearing clutch sub-assembly, rotate the pinion gear clockwise and check that the pinion gear turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

         If the result is not as specified, replace the starter center bearing clutch sub-assembly.

5. INSPECT MOTOR TERMINAL STARTER KIT

   1. 

      Check the plunger.

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

         If the result is not as specified, replace the motor terminal starter kit.

   2. 

      *1	Terminal 50
      *2	Terminal C

      Check the resistance.

      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

         If the result is not as specified, replace the motor terminal starter kit.

      2. 

         *1	Terminal 50
         *2	Motor terminal starter kit

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Motor terminal starter kit	Always	Below 2 Ω

         If the result is not as specified, replace the motor terminal starter kit.