STARTER(w/o Stop And Start System) 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. If not, the cable may become hot and cause injury.

   Note:

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

   1. Perform a pull-in test.

      1. 

         *a	Terminal 50
         *b	Body

         Connect the battery to the magnet starter switch assembly as shown in the illustration.

      2. Check that the clutch pinion gear moves outward.

         If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.

   2. 

      *a	Terminal 50
      *b	Body

      Check return operation.

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

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

   3. Perform a no-load performance test.

      1. Clamp the starter assembly in a vise between aluminum plates.

         Note:

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

      2. 

         *a	Terminal 50
         *b	Terminal 30
         *c	Body

         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 operates.

      3. Check that the starter rotates smoothly and steadily with the clutch pinion gear moved outward.

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

         Standard Current

         Tester Connection	Condition	Specified Condition
         Battery positive terminal - Terminal 30 - Terminal 50	11.5 V	Below 90 A

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

2. INSPECT STARTER ARMATURE ASSEMBLY

   1. Check the commutator for an open circuit.

      1. 

         *a

         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. Check the commutator for a short circuit.

      1. 

         *a	Commutator
         *b	Armature Coil Core

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Commutator - Armature coil core	Always	10 kΩ or higher

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

   3. Check the commutator for dirt and burns on the surface.

      If the surface is dirty or burnt, restore it with sandpaper (No. 400) or on a lathe.

   4. Check the commutator for runout.

      1. 

         Place the commutator on V-blocks.

      2. Using a dial indicator, measure the runout.

         Standard Runout

         0.02 mm (0.000787 in.)

         Maximum Runout

         0.05 mm (0.00197 in.)

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

   5. 

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter

      25.0 mm (0.984 in.)

      Minimum Diameter

      24.0 mm (0.945 in.)

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

   6. 

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

      Standard Undercut Depth

      0.7 mm (0.0276 in.)

      Minimum Undercut Depth

      0.2 mm (0.00787 in.)

      If the undercut depth is less than the minimum, adjust it with a hacksaw.

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   1. 

      Using a vernier caliper, measure the brush length.

      Standard Length

      11.6 mm (0.457 in.)

      Minimum Length

      7.6 mm (0.299 in.)

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

4. INSPECT STARTER CLUTCH SUB-ASSEMBLY

   1. 

      *a	Free
      *b	Lock

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

      If necessary, replace the starter clutch sub-assembly.

5. INSPECT MAGNET STARTER SWITCH ASSEMBLY

   1. Check the plunger.

      1. 

         *a

         Plunger

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

         If necessary, replace the magnet starter switch assembly.

   2. Check the holding coil for an open circuit.

      1. 

         *a	Terminal 50
         *b	Body

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Terminal 50 - Body	Always	Below 2 Ω

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