STARTER (w/ Stop And Start System) > INSPECTION

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1. INSPECT STARTER ASSEMBLY


A219728

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



  1. Perform a no-load performance test.

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

      Torque:
      10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    2. Clamp the starter in a vise.

      NOTICE:
      Do not clamp the vise too tightly.



      3. A219735E01

    3. Connect the battery and an ammeter to the starter as shown in the illustration.
      Text in Illustration 
      *1
      		Terminal 50
      *2
      		Terminal 30
      *3
      		Body
      *4
      		Ammeter

    4. Check that the starter operates smoothly and steadily.
      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 110 A

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



2. INSPECT STARTER WITH CLUTCH ARMATURE ASSEMBLY


    A199102E02

  1. Inspect the resistance of the commutator.

    1. Measure the resistance according to the value(s) in the table below.
      Text in Illustration 
      *1
      		Commutator

      Standard Resistance:
      Tester Connection
      		Condition
      		Specified Condition
      Segment - Segment
      		Always
      		Below 1 Ω

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



    A199101E03

  1. Inspect the resistance of the commutator for a short to ground.

    1. Measure the resistance according to the value(s) in the table below.
      Text in Illustration 
      *1
      		Armature Coil Core
      *2
      		Commutator

      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 with clutch 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.



    A199100

  1. Check the commutator for circle runout.

    1. Place the commutator on V-blocks.

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

      Standard runout:
      0.02 mm (0.000787 in.)

      Maximum runout:
      0.05 mm (0.00197 in.)

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



    A158858

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

    Standard diameter:
    29.0 mm (1.142 in.)

    Minimum diameter:
    28.0 mm (1.102 in.)

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



    A158859

  1. Check that the undercut portion is clean and free of foreign matter, with smooth edges.

    Standard undercut depth:
    0.7 mm (0.0276 in.)

    Minimum undercut depth:
    0.2 mm (0.00787 in.)

    If the undercut depth is less than the minimum, increase the depth using a hacksaw blade.



    A205231E03

  1. Inspect the clutch.
    Text in Illustration 
    *a
    		Free
    *b
    		Lock

    1. Rotate the armature counterclockwise and check that it turns freely, Try to rotate the armature clockwise and check that it locks, If necessary, replace the starter with clutch armature assembly.



3. INSPECT STARTER BRUSH HOLDER ASSEMBLY

  1. Remove the claw of the spring, and then remove the 4 brushes.



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


    A206796E03


    Text in Illustration 
    *1
    		Brush
    		*2
    		Spring
    *a
    		Length
    		-
    		-

    Standard length:
    14.4 mm (0.567 in.)

    Minimum length:
    9 mm (0.3543 in.)

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



    A206797E01

  1. Check the brush holder.

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

      Standard Resistance:
      Tester Connection
      		Condition
      		Specified Condition
      A - B
      		Always
      		10 kΩ or higher
      A - C
      		Always
      		10 kΩ or higher
      A - D
      		Always
      		Below 1 Ω
      B - C
      		Always
      		Below 1 Ω
      B - D
      		Always
      		10 kΩ or higher
      C - D
      		Always
      		10 kΩ or higher

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



4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

  1. Inspect the gear teeth on the planetary gear and internal gears for wear and damage.
    If damaged, replace the starter planetary gear or starter center bearing clutch sub-assembly. Also check the starter planetary gear for wear or damage.



5. INSPECT MAGNET STARTER SWITCH ASSEMBLY


    A206795

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



    A079726E15

  1. Check whether the coil has an open circuit.

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

      Standard Resistance:
      Tester Connection
      		Condition
      		Specified Condition
      Terminal 50 - Body
      		Always
      		Below 2 Ω

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