Starter -- Inspection |
| 1. INSPECT STARTER ASSEMBLY |
- CAUTION:
- As a large electric current passes through the cable during this inspection, a thick cable must be used. Otherwise, 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 disconnect the lead wire from terminal C.
Connect the battery to the starter as shown in the illustration. Then check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnet starter switch assembly.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 out.
If the clutch pinion gear returns inward, replace the magnet starter switch assembly.Text in Illustration *1 Terminal C
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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, replace the magnet starter switch assembly.
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Perform an operation test without load.
Connect the lead wire to terminal C with the nut.
- 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 moving out. Then measure the current.
- Specified current:
- 90 A or less at 11.5 V
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| 2. INSPECT MAGNET STARTER SWITCH ASSEMBLY |
Check the resistance.
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 50 *2 Terminal C 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 Terminal 50 *2 Switch Body
| 3. INSPECT BRUSH |
Using a vernier caliper, measure the brush length.
- Standard length:
- 15.5 mm (0.610 in.)
- Minimum length:
- 8.5 mm (0.335 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 |
Check the brush spring load.
Take a pull scale reading immediately after the brush spring separates from the brush.
- Standard spring load:
- 18 to 24 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf)
- Minimum spring load:
- 12 N (1 kgf, 2.7 lbf)
If the spring load is less than the minimum, replace the starter brush holder assembly.Text in Illustration *1 Brush *2 Brush Spring
Check the resistance.
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 Ω or higher
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| 5. INSPECT STARTER YOKE ASSEMBLY |
Check the resistance.
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 Starter yoke body - Brush Always 10 kΩ or higher
| 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.
If necessary, replace the starter armature assembly.
Check the resistance.
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 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 circle runout:
- 0.05 mm (0.00197 in.)
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Using a vernier caliper, measure the commutator diameter.
- Standard diameter:
- 30.0 mm (1.18 in.)
- Minimum diameter:
- 29.0 mm (1.14 in.)
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Using a vernier caliper, measure the undercut depth of the commutator.
- Standard undercut depth:
- 0.6 mm (0.0236 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.