Starter (For 3.0 Kw Type) -- Inspection |
| 1. INSPECT STARTER |
- 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:
- These tests must be performed within 3 to 5 seconds to prevent the coil from burning out.
Mount the starter in a vise between aluminum plates.
Perform pull-in test.
Remove the nut and disconnect the lead wire from terminal C.
Text in Illustration *1 Terminal C Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.
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 C *2 Terminal 50
Perform a holding test.
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.
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 (-) 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 with the nut.
- Torque:
- 24 N*m{245 kgf*cm, 18 ft.*lbf}
Connect the battery and an ammeter to the starter as shown in the illustration.
Check that the starter rotates smoothly and steadily while the pinion gear extended. Then measure the current.
- Standard current:
- 220 A or less at 11.5 V
If the result is not as specified, inspect the starter assemblyText in Illustration *1 Terminal 50 *2 Terminal 30 - 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 |
Check the pull-in coil for an open circuit.
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
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Check the hold-in coil for an open circuit.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Terminal 50 - Starter 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
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| 3. INSPECT BRUSH |
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Using a vernier caliper, measure the brush length.
- Standard length:
- 21.0 mm (0.828 in.)
- Minimum length:
- 12.0 mm (0.472 in.)
| 4. INSPECT STARTER BRUSH HOLDER ASSEMBLY |
Inspect the brush 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
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Take a pull scale reading the instant the brush spring separates from the brush.
- Standard spring load:
- 28 to 37 N (3 to 4 kgf, 6.3 to 8.3 lbf)
- Minimum spring load:
- 15 N (2 kgf, 3.4 lbf)
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| 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 Terminal C - Brush Always Below 1 Ω
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Inspect the field coil for ground.
Measure the resistance according to the value(s) in the table below.
- Standard Resistance:
Tester Connection Condition Specified Condition Terminal C - Starter yoke body Always 10 kΩ or higher
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| 6. INSPECT STARTER ARMATURE ASSEMBLY |
Check the commutator for dirt and/or burns on the surface.
If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe. If necessary, replace the starter armature assembly.
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
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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 Coil Core *2 Segment
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Inspect the commutator for circle runout.
Place the armature on V-blocks.
Using a dial gauge, 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 commutator diameter:
- 43.0 mm (1.69 in.)
- Minimum commutator diameter:
- 42.0 mm (1.65 in.)
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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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Inspect the bearings.
Check that the bearings rotate smoothly.
If the result is not as specified, replace the starter armature assembly.
| 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 brush holder 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 the result is not as specified, replace the starter brush holder assembly.