STARTER (for 0.8 kW Type) > INSPECTION

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1. INSPECT STARTER ASSEMBLY

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



    A198917

  1. Perform a pull-in test.

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



      2. A198921E01

    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 50
      *2
      		Terminal C
      *3
      		Body
      If the clutch pinion gear does not move, replace the magnet starter switch assembly.



    A198923E01

  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 50
      *2
      		Terminal C
      *3
      		Body
      If the clutch pinion gear returns inward, replace the magnet starter switch assembly.



    A198925E01

  1. Inspect the clutch pinion gear return.

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



    A198917

  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:
      9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

    2. Clamp the starter in a vise.

      NOTICE:
      Do not clamp the vise too tightly.



      3. A198929E01

    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. 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 90 A

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



2. INSPECT STARTER ARMATURE ASSEMBLY


  1. Check the commutator.



      A104566

    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.



  1. Check the commutator.



      A104565

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

      Standard Resistance:
      Tester Connection
      		Condition
      		Specified Condition
      Commutator - Armature core
      		Always
      		10 MΩ 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.



  1. Check the commutator for circle runout.



      A104575

    1. Place the commutator 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.



    A062221

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

    Standard diameter:
    28.0 mm (1.10 in.)

    Minimum diameter:
    27.0 mm (1.06 in.)

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



    A105577

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

    Standard undercut depth:
    0.6 mm (0.0236 in.)

    Minimum undercut depth:
    0.2 mm (0.00787 in.)

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



3. INSPECT FIELD COIL


    A142258E02

  1. Measure the resistance according to the value(s) in the table below.
    Text in Illustration 
    *1
    		Ohmmeter
    *2
    		Brush Lead
    *3
    		Terminal C

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    Terminal C - Brush lead
    		Always
    		Below 1 Ω

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



    A142259E02

  1. Measure the resistance according to the value(s) in the table below.
    Text in Illustration 
    *1
    		Ohmmeter
    *2
    		Brush Lead
    *3
    		Body

    Standard Resistance:
    Tester Connection
    		Condition
    		Specified Condition
    Brush lead - Body
    		Always
    		10 MΩ or higher

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



4. INSPECT STARTER BRUSH


    A142260

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

    Standard length:
    10.0 mm (0.394 in.)

    Minimum length:
    6.0 mm (0.236 in.)

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



5. REPLACE STARTER BRUSH


    A142261E02

  1. Cut the brush lead wire on the terminal side.
    Text in Illustration 
    *1
    		Cut



    A142262

  1. Smooth the brush lead wire using a file.

    NOTICE:
    Only a small area can be filed, do not damage the yoke.



    A142263E02

  1. Using pliers, pinch the plate of the brush (service part) on the weld side of the terminal lead wire and apply force.
    Text in Illustration  
    *1
    		Brush
    *2
    		Plate
    *3
    		Weld Side
    *4
    		Press



    A142264

  1. Apply solder to the contact surface.

    HINT:
    1. Heat the contact surface well. Apply a sufficient amount of solder to the inside of the plate while paying attention not to apply it to the lead wire.
    2. Do not apply solder to the field coil.



6. INSPECT STARTER BRUSH SPRING

  1. Check visually.

    Specified Condition:
    No rust, abrasion or damage.

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

    Standard length:
    21.5 mm (0.846 in.)



7. INSPECT STARTER CLUTCH SUB-ASSEMBLY


    A142257E02

  1. Hold the starter clutch, rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
    If necessary, replace the starter clutch sub-assembly.
    Text in Illustration  
    *1
    		Free
    *2
    		Look



8. INSPECT MAGNET STARTER SWITCH ASSEMBLY


  1. Check the plunger.



      A142249E02

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



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



      A079725E19

    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.



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



      A079725E20

    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.