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. 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 pull-in test.

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

*a	Terminal 50
*b	Terminal C
*c	Starter Body
	Moves outward

Connect a battery to the magnet switch as shown in the illustration. Check that the clutch pinion gear moves outward.

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

*a	Terminal 50
*b	Terminal C
*c	Starter Body
	Disconnect

Perform a hold-in test.

While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

*a	Terminal 50
*b	Starter Body
	Disconnect
	Returns inward

Perform a return test.

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.

Perform a no-load performance test.

Connect the field coil lead wire to terminal C with the nut. Make sure that the field coil lead wire is not grounded.

8.0 N*m

82 kgf*cm

71 in.*lbf
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.

*a	Terminal 30
*b	Terminal 50
*c	Starter Body
	Rotates

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 clutch pinion gear operates.

Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving 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 V	Below 70 A

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

INSPECT MAGNET STARTER SWITCH ASSEMBLY

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

*a	Terminal 50
*b	Terminal C

Check the pull-in coil for an open circuit.

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 magnet starter switch assembly.

*a	Terminal 50
*b	Magnet Switch Body

Check the holding coil for an open circuit.

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

Standard Resistance


Tester Connection	Condition	Specified Condition
Terminal 50 -Magnet switch body	Always	Below 2 Ω

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

INSPECT STARTER ARMATURE ASSEMBLY

Tip:

If there is no continuity between any segments, replace the 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


Tester Connection	Condition	Specified Condition
Segment - Segment	Always	2.67 to 3.29 Ω

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


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

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.

Standard Runout

0.05 mm (0.00197 in.)

Maximum Runout

0.07 mm (0.00276 in.)

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

Using a vernier caliper, measure the commutator diameter.

Standard Diameter

30.2 mm (1.19 in.)

Minimum Diameter

28.9 mm (1.14 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

1.43 mm (0.0563 in.)

Minimum Undercut Depth

0.75 mm (0.0295 in.)

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

INSPECT STARTER BRUSH HOLDER ASSEMBLY

*a	Length

Check the brush length.

Using a vernier caliper, measure the brush length.

Standard Length

12.3 mm (0.484 in.)

Minimum Length

9.8 mm (0.386 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


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

*a	Free
*b	Lock

Check the clutch pinion gear.

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.
If the clutch pinion gear does not operate as specified, replace the starter clutch sub-assembly.