STARTING SYSTEM INSPECTION


  1. INSPECT STARTER ASSEMBLY (for 1.6 kW Type)

    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

    The following tests must each 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 the pull-in test.


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

      2. B007RP1E01
        Text in Illustration
        *a Terminal 50
        *b Terminal C

        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.

    3. Perform the holding test.


      1. B007QK9E01
        Text in Illustration
        *a Terminal C

        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.

    4. Inspect the clutch pinion gear return.


      1. B007VP6E02
        Text in Illustration
        *a Starter Body

        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 magnet starter switch assembly.

    5. Perform the no-load performance test.


      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. B007T1LE01
        Text in Illustration
        *a Terminal 50
        *b Terminal 30
        *c AC/DC 400A Probe

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

      3. 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 ASSEMBLY (for 1.7 kW Type)

    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

    The following tests must each 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 pull-in test.


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

      2. B007PK6E03
        Text in Illustration
        *a Terminal 50
        *b Terminal C

        Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward. If the clutch pinion gear does not move, replace the magnet starter switch assembly.

    3. Perform holding test.


      1. B007QONE03
        Text in Illustration
        *a Terminal C

        When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear returns out.

        If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

    4. Inspect clutch pinion gear return.


      1. B007VBZE03
        Text in Illustration
        *a Starter Body

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

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

    5. Perform operation test without load.


      1. Connect the lead wire to terminal C.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      2. B007PDNE01
        Text in Illustration
        *a Terminal 50
        *b Terminal 30
        *c AC/DC 400A Probe

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.

        Standard current
        90 A or less at 10.9 V

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

  3. INSPECT STARTER ASSEMBLY (for 2.0 kW Type)

    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

    The following tests must each 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 pull-in test.


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

      2. B007RVEE03
        Text in Illustration
        *a Terminal 50
        *b Terminal C

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

    3. B007RUZE04
      Text in Illustration
      *a Terminal C

      Perform holding test.


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

        If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    4. B007Q79E02
      Text in Illustration
      *a Starter Body

      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 clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

    5. Perform operation test without load.


      1. Connect the lead wire to terminal C.

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }
      2. B007SUYE01
        Text in Illustration
        *a Terminal 50
        *b Terminal 30
        *c AC/DC 400A Probe

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

      3. Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.

        Standard current
        100 A or less at 11.5 V

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

        Tech Tips

        Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.