STARTER (for 2.0 kW Type) > INSPECTION

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1. INSPECT STARTER ASSEMBLY


A198946

NOTICE:
The following tests must be performed within 5 seconds to prevent the coil from burning out.



  1. Perform a pull-in test.

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



      2. A198938E02

    2. Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear is extended.
      Text in Illustration 
      *1
      		Terminal C
      *2
      		Terminal 50
      *3
      		Body
      If the clutch pinion gear does not move, replace the magnet starter switch assembly.



    A198940E02

  1. Perform a holding test.

    1. Disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear remains extended.
      Text in Illustration 
      *1
      		Terminal C
      *2
      		Terminal 50
      *3
      		Body
      If the clutch pinion gear returns inward, replace the magnet starter switch assembly.



    A198942E02

  1. Inspect the clutch pinion gear return.

    1. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns.
      Text in Illustration 
      *1
      		Terminal C
      *2
      		Terminal 50
      *3
      		Body
      If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.



    A198946

  1. Perform a no-load performance test.

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

      Torque:
      6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

    2. Clamp the starter in a vise.

      NOTICE:
      Do not clamp the vise to tightly.



      3. A198944E02

    3. Connect the battery and an ammeter to the starter as shown in the illustration.
      Text in Illustration 
      *1
      		Terminal 30
      *2
      		Terminal 50
      *3
      		Body

    4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended.
      Measure the current according to the value(s) in the table below.

      Standard Current:
      Tester Connection
      		Condition
      		Specified Condition
      Battery positive terminal - Terminal 30 - Terminal 50
      		11.5 V
      		Below 190 A

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



2. INSPECT MAGNET STARTER SWITCH ASSEMBLY


  1. Check the plunger.



      A033580

    1. Push in the plunger and check that it returns quickly to its original position.
      If necessary, replace the magnet starter switch assembly.



    A202470E02

  1. Check the pull-in coil for an open circuit.

    1. Measure the resistance according to the value(s) in the table below.
      Text in Illustration 
      *1
      		Terminal 50
      *2
      		Terminal C

      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.



    A202471E03

  1. Check the hold-in coil for an open circuit.

    1. Measure the resistance according to the value(s) in the table below.
      Text in Illustration 
      *1
      		Terminal 50
      *2
      		Switch Body

      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 ARMATURE ASSEMBLY


    A086442E02

  1. Check the commutator.

    1. 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.



    A086443E01

  1. Check the commutator.

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

      Standard Resistance:
      Tester Connection
      		Condition
      		Specified Condition
      Commutator - Armature coil core
      		Always
      		10 kΩ or higher

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

  1. Check the commutator surface for dirt and burns.
    If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.



    A145291E01

  1. Check the commutator for circle runout.
    Text in Illustration 
    *1
    		Armature shaft

    1. Place the armature shaft on V-blocks.

    2. Using a dial indicator, measure the circle runout.

      Maximum runout:
      0.05 mm (0.00197 in.)

      If the runout is greater than the maximum, replace the starter armature assembly.



    A086444

  1. Using a vernier caliper, measure the commutator diameter.

    Standard diameter:
    35.0 mm (1.378 in.)

    Minimum diameter:
    34.0 mm (1.339 in.)

    If the diameter is less than the minimum, replace the armature assembly.



    A062965

  1. Check that the undercut portion between the segments is free of foreign matter and measure its depth.

    Standard undercut depth:
    0.7 mm (0.0276 in.)

    Minimum undercut depth:
    0.2 mm (0.0079 in.)

    If the undercut depth is less than the minimum, adjust it with a hacksaw blade.



4. INSPECT STARTER YOKE ASSEMBLY


    A202465

  1. 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

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



    A202466

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

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    Brush - Starter yoke body
    		Always
    		10 kΩ or higher

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



5. INSPECT BRUSH


    A202467E01

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

    Standard length:
    15 mm (0.591 in.)

    Minimum length:
    9.0 mm (0.354 in.)

    If the brush length is less than the minimum, replace the starter yoke assembly.



6. INSPECT STARTER BRUSH HOLDER ASSEMBLY


    A202468

  1. 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

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



  1. Inspect the load of the brush spring.



      ST00019

    1. Take the pull scale reading immediately after the brush spring separates from the brush.

      Standard spring installed load:
      21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)

      Minimum spring installed load:
      12.3 N (1.3 kgf, 2.8 lbf)

      If the installed load is less than the minimum, replace the brush holder.



7. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

  1. Check the gear teeth of the planetary gear and starter center bearing clutch for wear or damage.
    If any planetary gear is damaged, replace the planetary gear assembly.
    If any gear of the starter center bearing clutch is damaged, replace the starter center bearing clutch sub-assembly.



    A202469E02

  1. Check the movement of the clutch pinion gear.
    Text in Illustration 
    *1
    		Free
    *2
    		Lock

    1. Hold the starter clutch, rotate the clutch pinion gear clockwise, and check that it turns freely.

    2. Try to rotate the clutch pinion gear counterclockwise and check that it locks.
      If the clutch pinion gear cannot be turned clockwise smoothly, or does not lock in the counterclockwise direction, replace the starter center bearing clutch sub-assembly.