STARTER INSPECTION

PROCEDURE

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:

The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.

Mount the starter in a vise between aluminum plates.

Perform a pull-in test.

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

Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.

Table 1. Text in Illustration
*1	Terminal 50
*2	Terminal C
	Moves Outward

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

Perform a holding test.

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 out.

Table 2. Text in Illustration
*1	Terminal C
	Disconnect

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

Inspect the clutch pinion gear return.

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

Table 3. Text in Illustration
	Disconnect
	Returns Inward

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

Perform an operation test without load.

Connect the lead wire to terminal C with the nut.

8.0 N*m

82 kgf*cm

71 in.*lbf

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

Table 4. Text in Illustration
*1	Terminal 30
*2	Terminal 50

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

Standard current

Below 90 A at 11.5 V

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

INSPECT STARTER ARMATURE ASSEMBLY

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.

Inspect the commutator for an open circuit.

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

Table 5. Text in Illustration
*1	Segment

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

Inspect the commutator for a short circuit.

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

Standard Resistance


Tester Connection	Condition	Specified Condition
Coil core - Segment	Always	10 kΩ or higher

Table 6. Text in Illustration
*1	Coil Core
*2	Segment

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

Check the commutator circle runout.
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  
  Standard circle runout
  
  0.02 mm (0.000787 in.)
  
  Maximum circle runout
  
  0.04 mm (0.00157 in.)
  
  If the circle runout is more than the maximum, correct the circle runout with sandpaper (No. 400) or replace the starter armature assembly.
Check the commutator diameter.
1. Using a vernier caliper, measure the commutator diameter.
  
  Standard diameter
  
  29.9 mm (1.17 in.)
  
  Minimum diameter
  
  28.8 mm (1.13 in.)
  
  If the diameter is less than the minimum, replace the starter armature assembly.
Check the undercut depth.
1. Using a vernier caliper, measure the undercut depth of the commutator.
  
  Standard depth
  
  0.9 mm (0.0354 in.)
  
  Minimum depth
  
  0.4 mm (0.0157 in.)
  
  If the undercut depth is less than the minimum, replace the starter armature assembly.

INSPECT STARTER BRUSH HOLDER ASSEMBLY

Check the brush length.

Using a vernier caliper, measure the brush length.

Standard length

10.5 mm (0.413 in.)

Minimum length

7.0 mm (0.276 in.)

Table 7. Text in Illustration
*1	Length

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

Inspect the brush insulation.

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	Always	Below 1 Ω

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

INSPECT STARTER 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.

Table 8. Text in Illustration
	Free
	Lock

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

INSPECT MAGNET STARTER SWITCH ASSEMBLY

Check the plunger.

Install the plunger and return spring to the switch body.

Table 9. Text in Illustration
*1	Switch Body
*2	Return Spring
*3	Plunger

Push in the plunger and check that it returns quickly to its original position.
If the result is not as specified, replace the magnet starter switch assembly.

Check the resistance.

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

Table 10. Text in Illustration
*1	Terminal 50
*2	Terminal C

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

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

Standard Resistance


Tester Connection	Condition	Specified Condition
Terminal 50 - Switch body	Always	Below 1.5 Ω

Table 11. Text in Illustration
*1	Switch Body
*2	Terminal 50

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