INSPECTION PROCEDURE 1. INSPECT STARTER ASSEMBLY
CAUTION: As a large electric current passes through the cable during this inspection, a think cable must be used.
If not, the cable may became hot and cause injury. NOTICE: Perform each of the following tests within 3 to 5 seconds.
| (a) Perform a pull-in test. (1) Remove the nut, and then disconnect the field coil lead wire from terminal C.
(2)
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, replace the magnet starter switch assembly. |
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| (b) Perform a holding test. (1)
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 moves inward, replace the magnet starter switch assembly. |
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| (c) Inspect the clutch pinion gear return. (1) 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, replace the magnet starter switch assembly. |
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(d) Perform an operation test without load. (1) Connect the field coil lead wire to terminal C.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} (2) Mount the starter in a vise between aluminum plates.
| (3) Connect the battery and ammeter to the starter as shown in the illustration. |
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(4) Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.
Standard current: 90 A or less at 11.5 V If the result is not as specified, replace the starter assembly.
2. INSPECT MAGNET STARTER SWITCH ASSEMBLY (a) Check the plunger.
| (1) Push in the plunger and check that it returns quickly to its original position.
If the result is not as specified, replace the magnet starter switch assembly. |
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| (b) Check if the pull-in coil has an open circuit. (1) 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. |
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| (c) Check if the holding coil has an open circuit. (1) Measure the resistance according to the value(s) in the table below.
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. |
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3. INSPECT STARTER ARMATURE ASSEMBLY (a) Check the appearance. If the surface is dirty or burnt, restore the surface with sandpaper (No. 400) or on a lathe.
(b) Measure the resistance. 
(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.
| (2) 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. |
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| (c) Check the commutator circle runout. (1) Place the armature shaft 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 circle runout is more than the maximum, replace the starter armature assembly. |
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| (d) Using a vernier caliper, measure the commutator diameter.
Standard diameter: 29.0 mm (1.14 in.) Minimum diameter:
28.0 mm (1.10 in.) If the diameter is less than the minimum, replace the starter armature assembly. |
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| (e) Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.
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. |
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4. INSPECT STARTER BRUSH HOLDER ASSEMBLY
| (a) Using a vernier caliper, measure the brush length. Standard length:
14.4 mm (0.567 in.) Minimum length: 9.0 mm (0.354 in.)
If the length is less than the minimum, replace the starter brush holder assembly. |
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| (b) Inspect the load of the brush spring. (1) Take a pull scale reading immediately after the brush spring separates from the brush.
Standard spring load: 16 to 20 N (1.7 to 2 kgf, 3.6 to 4.5 lbf)
Minimum spring load: 6.7 N (0.7 kgf, 1.5 lbf) If the load is less than the minimum, replace the starter brush holder assembly. |
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5. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY (a)
Check the gear teeth on the planet gears, and the internal gear and
pinion gear of the starter center bearing clutch for wear or damage. If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly.
| (b)
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 the result is not as specified, replace the starter center bearing clutch sub-assembly. |
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