Starter (For 2.0 Kw Type) -- 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.
- NOTICE:
- The following tests must each be performed within 3 to 5 seconds to prevent the coil from burning out.
Mount the starter in a vise between aluminum plates.
Perform a pull-in test.
Remove the nut, and then disconnect the lead wire from terminal C.
Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear extends.
If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.Text in Illustration *1 Terminal 50 *2 Terminal C
Perform a holding test.
Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains extended.
If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.Text in Illustration *1 Terminal C
Inspect the clutch pinion gear return.
Disconnect the negative (-) terminal lead from the starter body. Check that the clutch pinion gear returns inward.
If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.
Perform an operation test without load.
Connect the lead wire to terminal C.
- Torque:
- 5.9 N*m{60 kgf*cm, 52 in.*lbf}
Connect the battery and an ammeter to the starter as shown in the illustration.
Text in Illustration *1 Terminal 50 *2 Terminal 30 Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.
- Specified Current:
- 100 A or less at 11.5 V
- HINT:
- Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.
| 2. INSPECT MAGNET STARTER SWITCH ASSEMBLY |
Inspect the pull-in coil.
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.Text in Illustration *1 Terminal C *2 Terminal 50
Inspect the holding coil.
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.Text in Illustration *1 Switch Body *2 Terminal 50
| 3. INSPECT BRUSH |
Using a vernier caliper, measure the brush length.
- Standard length:
- 15.0 mm (0.591 in.)
- Minimum length:
- 9.0 mm (0.354 in.)
If the length is less than the minimum, replace the starter brush holder assembly and starter yoke assembly.Text in Illustration *1 Length *a Brush Holder Side *b Starter Yoke Side
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| 4. INSPECT STARTER BRUSH HOLDER ASSEMBLY |
Inspect the insulation.
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
Check the brush spring load.
Take a pull scale reading as soon as the brush spring separates from the brush.
- Standard spring load:
- 22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)
- Minimum spring load:
- 12 N (1 kgf, 2.8 lbf)
If the spring load is less than the minimum, replace the starter brush holder assembly.Text in Illustration *1 Brush Spring *2 Brush
| 5. INSPECT STARTER YOKE ASSEMBLY |
Inspect the field coil for an open circuit.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Lead wire - Brush Always Below 1 Ω
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Terminal A -Terminal B 20°C (68°F) 1.5 to 1.9 Ω
If the result is not as specified, replace the starter yoke assembly.Text in Illustration *1 Terminal A *2 Terminal B
| 6. INSPECT STARTER ARMATURE ASSEMBLY |
Check the commutator for dirt and/or burns on the surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
Inspect the commutator for an open circuit.
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.Text in Illustration *1 Segment
Inspect the commutator for a short circuit.
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.Text in Illustration *1 Segment *2 Coil Core
Check the commutator circle runout.
Place the commutator on V-blocks.
Using a dial indicator, measure the circle runout.
- Maximum runout:
- 0.05 mm (0.00197 in.)
Check the commutator diameter.
Using a vernier caliper, measure the commutator diameter.
- Standard diameter:
- 35.0 mm (1.38 in.)
- Minimum diameter:
- 34.0 mm (1.34 in.)
Check the undercut depth.
Using a vernier caliper, measure the undercut depth of the commutator.
- Standard undercut depth:
- 0.7 mm (0.0276 in.)
- Minimum undercut depth:
- 0.2 mm (0.00787 in.)
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| 7. INSPECT STARTER CLUTCH SUB-ASSEMBLY |
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 clutch sub-assembly.Text in Illustration 
Free 
Lock
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Turn the pinion gear by hand while applying inward force and check the movement of the bearing.
If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.