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

      2. 

         *a	Terminal C
         *b	Terminal 50

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

      3. Check that the clutch pinion gear moves outward.

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

   2. 

      Perform a hold-in 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 moves outward.

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

   3. 

      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 starter magnetic switch assembly.

   4. Perform a no-load performance test.

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

         6.5 N*m

         66 kgf*cm

         58 in.*lbf

      2. 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.

      3. 

         *a	Terminal 30
         *b	Terminal 50
         *c	Terminal C

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

         Note:

         Do not allow any lead to get caught as the pinion gear operates.

      4. 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 190 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. 

         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. 

         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 appearance.

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

   4. Check the commutator for runout.

      1. 

         *a	Armature Shaft

         Place the armature shaft 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

      35.0 mm (1.37 in.)

      Minimum Diameter

      34.0 mm (1.34 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 YOKE ASSEMBLY

   1. Inspect the resistance of the field coil.

      1. 

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Lead wire - Brush	Always	Below 1 Ω

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

      2. 

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

         Standard Resistance

         Tester Connection	Condition	Specified Condition
         Brush - Starter yoke body	Always	10 kΩ or higher

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

4. INSPECT BRUSH

   1. 

      *A	Brush Holder Side
      *B	Yoke Side
      *a	Length

      Using a vernier caliper, measure the brush length.

      Standard Length

      15.0 mm (0.591 in.)

      Minimum Length

      9.0 mm (0.354 in.)

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

5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   1. Inspect the insulation.

      1. 

         Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

         Standard Resistance

         10 kΩ or higher

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

   2. Inspect the load of the brush spring.

      1. 

         Take the pull scale reading immediately after the brush spring separates from the brush.

         Standard Spring Installed Load

         21.5 to 27.5 N (2 to 3 kgf, 4.8 to 6.2 lbf)

         Minimum Spring Installed Load

         12 N (1 kgf, 2.7 lbf)

         If the installed load is less than the minimum, replace the brush springs.

6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

   1. Inspect the gear teeth of the planetary gears and internal gear of the starter center bearing clutch sub-assembly for wear or damage.

      If damaged, replace the planetary gears or starter center bearing clutch sub-assembly. Also check the planetary gears for wear and damage.

   2. 

      *a	Free
      *b	Lock

      Check the movement of the clutch pinion gear.

      1. Rotate the clutch pinion gear clockwise and check that it turns freely.

      2. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

         If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.

7. INSPECT STARTER MAGNETIC SWITCH ASSEMBLY

   1. 

      Check the plunger.

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

         If necessary, replace the starter magnetic switch assembly.

   2. Check the pull-in coil for an open circuit.

      1. 

         *a	Terminal 50
         *b	Terminal C

         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 starter magnetic switch assembly.

   3. Inspect the resistance of the hold-in coil.

      1. 

         *a	Terminal 50
         *b	Switch Body

         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 2 Ω

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