STARTER (for 2.2 kW Type Bosch Made) INSPECTION


  1. INSPECT STARTER ASSEMBLY

    Note

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

    A01E1RNE01

    1. Perform pull-in test.


      1. Remove the nut, and then disconnect the field coil core from terminal C.

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

        A01DYXIE01

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

    2. Perform holding test.


      1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.

        A01DYFBE01

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

    3. Inspect clutch pinion gear return.


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

        A01DYYUE01

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

    4. Perform operation test without load.


      1. Connect the field coil lead wire to terminal C with the nut.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      2. Mount the starter in a vise between aluminum plates.

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

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

        Standard current
        123 A or less at 11.5 V
        A01E13XE01

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

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01DV6T

      Measure the resistance.


      1. Measure the resistance between the segments of the commutator.

        Standard resistance
        Below 1.7 Ω

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

      2. A01DWMJ

        Measure the resistance between a segment of the commutator and armature coil core.

        Standard resistance
        10 kΩ or higher

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

    2. A01DXEG

      Inspect the commutator circle runout.


      1. Place the commutator on V-blocks.

      2. Using a dial indicator, measure the circle runout.

        Standard runout
        0.02 mm (0.0008 in.)
        Maximum runout
        0.04 mm (0.0016 in.)

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

    3. A01DYTZ

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      32.2 mm (1.2783 in.)
      Minimum diameter
      31.1 mm (1.2347 in.)

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

    4. A01DYEN

      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 depth is less than the minimum, replace the armature assembly.

  3. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01E2Z3

      Using a vernier caliper, measure the brush length.

      Standard length
      14.0 mm (0.5558 in.)
      Minimum length
      9.0 mm (0.3543 in.)

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

    2. A01E0DZE01

      Check the brush holder.


      1. Measure the resistance between the brushes.

        Standard resistance
        Tester Connection Specified Condition
        A - B 10 kΩ or higher
        A - C 10 kΩ or higher
        A - D Below 1 Ω
        B - C Below 1 Ω
        B - D 10 kΩ or higher
        C - D 10 kΩ or higher

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

  4. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01E24FE01

      Check the starter clutch pinion gear.


      1. Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

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

  5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01DWGNE01

      Check the plunger.


      1. Install the plunger and spring onto the switch body.

      2. A01DVYZ

        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 assemby.

    2. A01E27TE01

      Check if the pull-in coil has an open circuit.


      1. Measure the resistance between terminal 50 and terminal C.

        Standard resistance
        Below 1 Ω

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

    3. A01DVGCE01

      Check if the hold-in coil has an open circuit.


      1. Measure the resistance between terminal 50 and the switch body.

        Standard resistance
        Below 2 Ω

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