Starter motor inspection (RZ4E-TC)

1. Starter motor inspection

1. Visual inspection

1) Inspect the overrunning clutch gear teeth for the following.

  • Excessive wear
  • Damage

2) Turn the overrunning clutch pinion by hand and inspect for the following.

  • Smooth rotation when turning in the clockwise direction
  • The pinion locks when turned in the counter-clockwise direction.

Note

  • Replace the overrunning clutch if a malfunction is found.

3) Inspect the internal gear for the following.

  • Abnormal wear
  • Damage

Note

  • Replace the internal gear if an abnormal condition is found.

4) Inspect the shift lever for the following.

  • Abnormal wear
  • Damage

Note

  • Replace the shift lever if an abnormal condition is found.

Legend

  1. Sliding section

2. Armature inspection

1) Make sure there is no short circuit inside the armature coil using a growler tester.

2) Measure the runout of the commutator using a dial gauge.

Note

  • Replace the armature if the measured value exceeds the limit.

Limit: 0.05 mm { 0.00197 in }

3) Measure the depth of the mica section of the commutator.

Note

  • If the mica segment depth is less than or equal to the standard value but more than the limit, the commutator can be reground.
  • If the mica segment depth is less than the limit, the armature must be replaced.

Limit: 0.2 mm { 0.008 in }

Legend

  1. Mica segment
  2. Commutator section
  3. Normal
  4. Defective

Legend

a. Mica segment depth

4) Measure the outer diameter of the commutator using a vernier caliper.

Standard: 29.0 mm { 1.142 in }

Limit: 28.0 mm { 1.102 in }

Note

  • Replace the armature if the measured value exceeds the limit.

5) Apply the probe to the commutator section and armature core, and inspect for poor insulation at the armature using a DMM.

Note

  • Replace the armature if a malfunction is found.

6) Apply the probe to the 2 commutator sections, and inspect for continuity at the armature using a DMM.

Note

  • There should be continuity between all segments of the commutator.
  • If there is no continuity, replace the armature.

3. Brush inspection

1) Measure the brush length of the 4 brushes using a vernier caliper.

Caution

  • If the length of any of the brushes is shorter than the limit, replace all brushes.
  • If there is excessive wear on a negative brush, replace the entire brush holder.
  • If there is excessive wear on a positive brush, replace the entire yoke.

Limit: 7 mm { 0.28 in }

2) Apply the probe to the holder plate and positive brush holder, and inspect for poor insulation at the brush holder using a DMM.

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