СТАРТЕР ПРОВЕРКА


  1. INSPECT STARTER ASSEMBLY

    Note

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


    1. A01DZ3IE01

      Perform pull-in test.


      1. Disconnect the field coil lead wire from terminal C.

      2. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.

    2. A01E0UJE01

      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.

    3. A01E1DWE01

      Inspect clutch pinion gear return.


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

    4. A01DYFNE01

      Perform the operation test without load.


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

        Torque:
        5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

      2. Grip the starter in a vise.

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

      4. Check that the ammeter displays the specified current.

        Specified current
        120 A or less at 11.5 V

  2. INSPECT STARTER ARMATURE ASSEMBLY


    1. A01E2ITE01

      Inspect the commutator for an open circuit.


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

        Standard resistance
        Below 1 Ω

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

    2. A01E15IE01

      Inspect the commutator for a short circuit.


      1. Using an ohmmeter, check that there is no resistance between the commutator and armature core.

        Standard resistance
        10 kΩ or higher

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

    3. A01E1YGE01

      Inspect the commutator circle runout.


      1. Place the armature on the V-blocks.

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

        Maximum circle runout
        0.05 mm (0.0020 in.)

        • If the runout is greater than the maximum, correct it with sandpaper (#400) or replace the armature assembly.

    4. A01DY9KE01

      Using a vernier caliper, measure the commutator diameter.

      Standard diameter
      35.0 mm (1.378 in.)
      Minimum diameter
      34.0 mm (1.339 in.)

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

    5. A01E1IDE01

      Measure the undercut depth of the commutator.

      Standard depth
      0.7 mm (0.028 in.)
      Minimum depth
      0.2 mm (0.008 in.)

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

    6. Inspect the bearings.


      1. Check that the bearings rotate smoothly.

        If necessary, replace them.

  3. INSPECT STARTER YOKE ASSEMBLY


    1. A01E0BZE01

      Inspect for an open circuit.


      1. Measure the resistance between the terminal C wire and brushes.

        Standard resistance
        Below 1 Ω

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

    2. A01DWGFE01

      Inspect for a short circuit.


      1. Measure the resistance between the terminal C wire and starter yoke body.

        Standard resistance
        10 kΩ or higher

      2. Measure the resistance between the brushes and starter yoke body.

        Standard resistance
        10 kΩ or higher

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

  4. INSPECT BRUSH


    1. A01E2O9E01

      Using a vernier caliper, measure the brush length.

      Standard brush length
      16.5 mm (0.650 in.)
      Minimum brush length
      9.0 mm (0.354 in.)

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

  5. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    1. A01DYY2E01

      Measure the resistance between the positive and negative brush holders.

      Standard resistance
      10 kΩ or higher

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

    2. A01E0IDE02

      Using a pull scale, measure the brush spring load.

      Standard spring load
      26.5 to 32.3 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)
      Minimum spring load
      17.6 N (1.8 kgf, 4.0 lbf)

      • If the spring load is less than the minimum, replace the brush holder.

  6. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    1. A01DV5BE01

      Check that the starter clutch operates.


      • If the starter clutch does not operate, replace it.

  7. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    1. A01DZ45E01

      Inspect the pull-in coil.


      1. Measure the resistance between terminals 50 and C.

        Standard resistance
        Below 1 Ω

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

    2. A01DZJNE01

      Inspect the holding coil.


      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 assembly.