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. Otherwise, the cable may become hot and cause injury.

    Note:

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

    1. Mount the starter assembly in a vise between aluminum plates.

      1. A156605C04

        *1

        Body

        *2

        Terminal C

        *3

        Terminal 50

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

      2. Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear is extended.

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

    2. Perform a holding test.

      1. A156606C03

        *1

        Body

        *2

        Terminal C

        *3

        Terminal 50

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

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

    3. Check the operation.

      1. A156607C04

        *1

        Body

        *2

        Terminal C

        *3

        Terminal 50

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

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

    4. Perform an operation test without load.

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

        9.8 N*m

        100 kgf*cm

        87 in.*lbf

      2. A197934C02

        *1

        Body

        *2

        Terminal 50

        *3

        Terminal 30

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

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

        Standard current

        90 A or less at 11.5 V

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

  2. INSPECT STARTER ARMATURE ASSEMBLY

    A122065

    1. Check the commutator for open circuits.

      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. A122066

      Check the commutator for ground.

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

        Standard Resistance

        Tester Connection

        Condition

        Specified Condition

        Segment - Coil Core

        Always

        Below 1 Ω

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

    3. Check the commutator surface for dirt and burns.

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

    4. A122067

      Check the commutator for circle runout.

      1. Place the commutator on V-blocks.

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

        Maximum Runout

        0.05 mm (0.00196 in.)

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

    5. A122068

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter

      28.0 mm (1.10 in.)

      Minimum Diameter

      27.0 mm (1.06 in.)

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

    6. A158859

      Check that the undercut portion between the segments is free of foreign matter and measure its depth.

      Standard Undercut Depth

      0.6 mm (0.0236 in.)

      Minimum Undercut Depth

      0.2 mm (0.00787 in.)

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

  3. INSPECT STARTER YOKE ASSEMBLY

    A158860C03

    *1

    Field Coil Brush Lead

    *2

    Terminal C

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      Terminal C - Brush lead

      Always

      Below 1 Ω

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

    2. A158861C03

      *1

      Field Coil Brush Lead

      *2

      Starter Yoke Body

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      Brush lead - Body

      Always

      10 kΩ or higher

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

  4. INSPECT BRUSH

    1. A300699

      Using a vernier caliper, measure the brush length.

      Standard Length

      14 mm (0.551 in.)

      Minimum Length

      9 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

    1. A153747N05

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

      Standard Resistance

      Tester Connection

      Condition

      Specified Condition

      Positive (+) brush holder - Negative (-) brush holder

      Always

      10 kΩ or higher

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

  6. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

    A158862C01

    *a

    Free

    *b

    Lock

    1. Hold the starter clutch and 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 center bearing clutch sub-assembly.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY

    A300700

    1. Check the plunger.

      1. 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.

    2. A156363C01

      *1

      Terminal 50

      *2

      Terminal C

      Check the pull-in coil for an open circuit.

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

        Standard Resistance

        Tester Connection

        Condition

        Specified Condition

        Terminal 50 - Body

        Always

        Below 1 Ω

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

    3. A156364C01

      *1

      Terminal 50

      *2

      Magnet Starter Switch Body

      Check whether the holding coil has an open circuit.

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

        Standard Resistance

        Tester Connection

        Condition

        Specified Condition

        Terminal 50 - Body

        Always

        Below 2 Ω

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