1. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.
2. Check for runout on the commutator. If excessive, replace the armature.
Commutator runout:
Standard
0.05 mm (0.0020 in)
Limit
0.10 mm (0.0039 in)
|
(A) |
Dial gauge |
|
(B) |
V-block |
3. Check the depth of the segment mold. If it is not within the standard, replace the armature.
Depth of segment mold:
Standard
0.50 mm (0.020 in)
|
(A) |
Depth of mold |
|
(B) |
Segment |
|
(C) |
Mold |
4. Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature.
|
(A) |
Steel sheet |
|
(B) |
Growler tester |
5. Use a circuit tester to touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is continuity, replace the armature.
Make sure that the pole is set at the predetermined position.
Inspect the pinion, and if there is any wear or damage, replace the overrunning clutch. Also, check that the pinion rotates counterclockwise smoothly and does not rotate clockwise. If there is any fault, replace the overrunning clutch.
CAUTION:
To prevent spilling of grease, do not clean the overrunning clutch with oil.
1. Visually check the brush. If there is any abnormal wear or cracks, replace the brush.
2. Measure the length of the brush. If it exceeds service limits, replace the brush.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
|
(A) |
Service limit line |
|
(B) |
Brush |
3. Check that the brush moves smoothly in the brush holder.
4. Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38 lbf) (In case of new parts)
Service limit
2.5 N (0.25 kgf, 0.56 lbf)
Using a circuit tester (set to “ohm”), check that there is continuity between terminals S and M, and between terminal S and ground. Also check to be sure there is no continuity between terminals M and B.
Resistance between switch assembly terminals:
|
Terminals |
Standard |
|
S — M |
1 Ω or less |
|
S — Ground |
1 Ω or less |
|
M — B |
1 MΩ or more |
|
(A) |
Terminal S |
|
(B) |
Terminal M |
|
(C) |
Terminal B |
1. Using a lead wire, connect the switch assembly terminal S to the positive terminal of battery, and the starter body to the ground terminal of battery. The pinion should be forced endwise on shaft.
NOTE:
With the pinion forced endwise on shaft, starter motor can sometimes rotate because current flows, through pull-in coil, to motor. This is not a problem.
2. Disconnect the connector from terminal M. Then using a lead wire, connect the positive terminal of battery and terminal M and ground terminal to starter body.
In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver.
|
(A) |
Terminal S |
|
(B) |
Terminal M |
The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine.
Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test.
For these performance tests, use the circuit shown in figure.
|
(A) |
Variable resistance |
|
(B) |
Magnet switch |
|
(C) |
Starter body |
1. Adjust the variable resistance with the switch on until the voltage is 11 V, and read the value displayed by the ammeter to measure starter speed. Compare these values with the standard.
No-load test (standard):
Voltage/Current
MT model and 1.5 L AT model
Max. 11 V/95 A or less
2.0 L AT model
Max. 11 V/90 A or less
Rotating speed
MT model and 1.5 L AT model
2,500 rpm or more
2.0 L AT model
2,000 rpm or more
2. Apply the specified braking torque to starter. The condition is normal if the current draw and starter speed are within standard.
Load test (standard):
Voltage/Load
MT model and 1.5 L AT model
7.5 V/8.84 N·m (0.9 kgf-m, 6.5 ft-lb)
2.0 L AT model
7.7 V/16.7 N·m (1.7 kgf-m, 12.3 ft-lb)
Current/Speed
MT model and 1.5 L AT model
300 A/870 rpm or more
2.0 L AT model
400 A/710 rpm or more
3. With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to standard voltage.
Lock test (standard):
Voltage/Current
MT model and 1.5 L AT model
4 V/680 A or less
2.0 L AT model
3.5 V/960 A or less
Torque
MT model and 1.5 L AT model
17 N·m (1.7 kgf-m, 12.5 ft-lb) or more
2.0 L AT model
31 N·m (3.2 kgf-m, 22.9 ft-lb) or more
Check that the starter do not have deformation, cracks and any other damage.