STARTING SYSTEM INSPECTION


  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

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


    1. Mount 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.

    2. Perform pull-in test.


      1. B007RNT

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

      2. B007QRYE04
        Text in Illustration
        *a Terminal 50
        *b Terminal C
        B007USN Moves Outward

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

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

    3. Perform holding test.


      1. B007VPWE01
        Text in Illustration
        *a Terminal C
        B007USN Disconnect

        Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the clutch pinion gear remains out.

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

    4. Check the return operation.


      1. B007SPO

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

        Text in Illustration
        B007USN Disconnect
        B007QIC Returns Inward

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

    5. Perform operation test no-load.


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

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      2. B007OIYE03
        Text in Illustration
        *a Terminal 30
        *b Terminal 50

        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.

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

        Standard current
        90 A or less at 11.5 V

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