STARTER(w/ Stop And Start System) 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 no-load performance test.

      1. 

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

         10 N*m

         102 kgf*cm

         7 ft.*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 50
         *b	Terminal 30
         *c	Body
         *d	Ammeter

         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 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 110 A

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

2. INSPECT STARTER WITH CLUTCH ARMATURE ASSEMBLY

   1. 

      *a	Commutator

      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 with clutch armature assembly.

   2. 

      *a	Armature Coil Core
      *b	Commutator

      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 with clutch 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. Place the commutator 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 with clutch armature assembly.

   5. 

      Using a vernier caliper, measure the commutator diameter.

      Standard Diameter

      29.0 mm (1.14 in.)

      Minimum Diameter

      28.0 mm (1.10 in.)

      If the diameter is less than the minimum, replace the starter with clutch 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.

   7. 

      *a	Free
      *b	Lock

      Check the clutch.

      1. While holding the starter with clutch armature assembly, rotate the armature counterclockwise and check that it turns freely. Try to rotate the armature clockwise and check that it locks. If necessary, replace the starter with clutch armature assembly.

3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

   1. Remove the claw of the spring, and then remove the 4 brushes.

   2. Using a vernier caliper, measure the brush length.

      

      *a	Brush	*b	Spring
      *c	Length	-	-

      Standard Length

      14.4 mm (0.567 in.)

      Minimum Length

      9 mm (0.354 in.)

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

   3. 

      Check the starter brush holder assembly.

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

         Standard Resistance

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

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

4. 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 and damage.

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

5. INSPECT REPAIR SERVICE STARTER KIT

   1. 

      Check the plunger.

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

         If necessary, replace the repair service starter kit.

   2. 

      *a	Terminal 50
      *b	Body

      Check the holding 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 2 Ω

         If the result is not as specified, replace the repair service starter kit.