PROCEDURE
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.
Perform a no-load performance test.
*a | Starter Body |
Moves outward |
Connect the positive (+) lead to terminal SL1.
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 starter kit.
*a | Starter Body |
Disconnect | |
Returns inward |
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 starter kit.
*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 starter motor.
If the result is not as specified, replace the repair service starter kit.
Secure 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.
Connect the battery and an AC/DC 400A probe to the starter assembly as shown in the illustration.
*a | Starter Body | *b | Terminal 30 |
*c | AC/DC 400A Probe | - | - |
Rotates | - | - |
Connect terminal SL2 and measure the current after the AC/DC 400A probe reading has stabilized.
Standard Current | ||||||
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If the result is not as specified, replace the repair service starter kit.
INSPECT STARTER ARMATURE ASSEMBLY
Check the commutator appearance.
If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.
*a | Segment |
Check the commutator for an open circuit.
Measure the resistance according to the value(s) in the table below.
Standard Resistance | ||||||
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If the result is not as specified, replace the starter armature assembly.
*a | Segment |
*b | Starter Armature Core |
Check the commutator for a short circuit.
Measure the resistance according to the value(s) in the table below.
Standard Resistance | ||||||
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If the result is not as specified, replace the starter armature assembly.
*a | Armature Shaft |
Check the commutator for runout.
Place the armature shaft on V-blocks.
Using a dial indicator, measure the runout.
Maximum Runout |
---|
0.05 mm (0.00197 in.) |
If the runout is greater than the maximum, replace the starter armature assembly.
Using a vernier caliper, measure the commutator diameter.
Standard Diameter |
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29 mm (1.1417 in.) |
Minimum Diameter |
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28 mm (1.1024 in.) |
If the diameter is less than the minimum, replace the starter armature assembly.
Check that the undercut portion between the segments is free of foreign matter and measure its depth.
Standard Undercut Depth |
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0.4 mm (0.0157 in.) |
Minimum Undercut Depth |
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0.2 mm (0.00787 in.) |
If the undercut depth is less than the minimum, replace the starter armature assembly.
INSPECT STARTER BRUSH HOLDER ASSEMBLY
*a | Length |
Check the brush length.
Using a vernier caliper, measure the brush length.
Standard Length |
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14.4 mm (0.567 in.) |
Minimum Length |
---|
9.0 mm (0.354 in.) |
If the length is less than the minimum, replace the starter brush holder assembly.
Check the brush holder resistance.
Measure the resistance according to the value(s) in the table below.
Standard Resistance | ||||||||
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If the result is not as specified, replace the starter brush holder assembly.
Check the brush spring load.
Take a pull scale reading the instant the brush spring separates from the brush.
Standard Spring Load |
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22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf) |
Minimum Spring Load |
---|
13.8 N (1.41 kgf, 3.1 lbf) |
If the spring load is less than the minimum, replace the starter brush holder assembly.
INSPECT STARTER CLUTCH
*a | Free |
*b | Lock |
Check the clutch pinion gear.
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 the clutch pinion gear does not operate as specified, replace the starter drive housing assembly.
INSPECT REPAIR SERVICE STARTER KIT
Check the plunger.
Push in the plunger and check that it returns quickly to its original position.
Note
Do not drop the plunger.
If the plunger does not operate as specified, replace the repair service starter kit.
*a | Magnet Switch Body |
Check the repair service starter kit resistance.
Measure the resistance according to the value(s) in the table below.
Standard Resistance | ||||||||
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If the result is not as specified, replace the repair service starter kit.