STARTER(for 1.7 kW Type) 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 be hot and cause injury.

    Note

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


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

      Note

      Ensure that the starter assembly is secured firmly in the vise to prevent it from falling out.

    2. Perform a pull-in test.


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

      2. B0059E5C03
        *a Terminal 50
        *b Terminal C
        B008IUL Moves Outward

        Connect the battery to the starter assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

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

    3. B00570EC06
      *a Terminal C
      B008IUL Disconnect

      Perform a holding test.


      1. Maintain the battery connections of the pull-in test above, but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

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

    4. B0059SIC01
      B008IUL Disconnect
      B008H52 Returns Inward

      Check the clutch pinion gear return.


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

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

    5. Perform a no-load performance test.


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

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. B0058J6C03
        *a Terminal 30
        *b Terminal 50
        *c AC/DC 400 A Probe

        Connect the battery and an ammeter (AC/DC 400 A probe) to the starter assembly as shown in the illustration.

        Note

        Do not allow any leads to get caught as the pinion gear operates.

      3. Check that the starter rotates smoothly and steadily while the 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 MAGNET STARTER SWITCH ASSEMBLY


    1. B0057CD

      Check the plunger.


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

        Note

        To avoid damaging the inside of the magnet switch, do not release the plunger quickly.

        If necessary, replace the magnet starter switch assembly.

    2. B005AYCC03
      *a Terminal 50
      *b Terminal C

      Check the pull-in coil.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Terminal C Always Below 1 Ω

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

    3. B0059X2C03
      *a Terminal 50
      *b Switch Body

      Check the hold-in coil.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Terminal 50 - Switch body Always Below 2 Ω

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

  3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B00570IC03
      *a Length

      Check the brush length.


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

        Standard length
        9.0 mm (0.354 in.)
        Minimum length
        4.0 mm (0.157 in.)

        If the length is less than the minimum, replace the starter commutator end frame assembly.

    2. B00594M

      Check the starter commutator end frame resistance.


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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush - Negative (-) brush Always 10 kΩ or higher

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

  4. INSPECT STARTER ARMATURE ASSEMBLY

    Tech Tips

    If there is no continuity between any segments, replace the starter armature assembly.


    1. Check the commutator for contamination and burns on its surface.

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

    2. Check the commutator for an open circuit.


      1. B005A07C06
        *a Segment

        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.

    3. Check the commutator for a short circuit.


      1. B0057RQC06
        *a Segment
        *b Coil Core

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

        Standard Resistance
        Tester Connection Condition Specified Condition
        Segment - Coil core Always 10 kΩ or higher

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

    4. B005A6JC03
      *a Length

      Using a vernier caliper, measure the commutator length.

      Standard length
      3.1 mm (0.122 in.)
      Maximum length
      3.8 mm (0.150 in.)

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

  5. INSPECT REPAIR SERVICE STARTER KIT


    1. B00598IC01
      B008IUL Free
      B008H52 Lock

      Check the starter clutch.


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

        If necessary, replace the repair service starter kit.