STARTER INSPECTION [ZJ, ZY]

id011915800300


On-vehicle Inspection

1.  Verify that the battery is fully charged.

2.  The starter is normal if it rotates smoothly and without any noise when the engine is cranked.

•  If the starter does not operate, inspect the following:
―  Remove the starter, and inspect the starter unit.
―  Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch (ATX).


No-load Test

1.  Verify that the battery is fully charged.

2.  Connect the starter, battery, and a tester as shown in the figure.

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3.  Operate the starter and verify that it rotates smoothly.

•  If the starter does not rotate smoothly, inspect the starter unit.

4.  Measure the voltage and current while the starter is operating.

•  If not within the specification, replace the starter.
Starter no-load test voltage
11 V
Starter no-load test current
ZJ38*: 95 A or less
ZJ45*: 90 A or less
*  :The first four digits of the part number indicated on the starter nameplate
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Magnetic Switch Operation Inspection


Pull-out test

Note
•  Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.

1.  Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded.

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•  If the starter motor pinion is not extended, repair or replace the starter.


Return test

1.  Disconnect the motor wire from terminal M.

2.  Connect battery positive voltage to terminal M and ground the starter body.

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3.  Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.

•  If it does not return, repair or replace the starter.


Pinion Gap Inspection

1.  Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded.

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Caution
•  Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s.

2.  Measure the pinion gap while the drive pinion is extended.

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•  If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).
Starter pinion gap
0.5—2.0 mm {0.02—0.07 in}


Starter Inner Parts Inspection


Armature

1.  Verify that there is no continuity between the commutator and the core at each segment using a tester.

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•  If there is continuity, replace the armature.

2.  Verify that there is no continuity between the commutator and the shaft using a tester.

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•  If there is continuity, replace the armature.

3.  Place the armature on V‐blocks, and measure the runout using a dial indicator.

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•  If it exceeds the maximum specification, replace the armature.
Starter armature runout
0.1 mm {0.004 in} max.

4.  Measure the commutator diameter.

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•  If not within the minimum specification, replace the armature.
Starter commutator diameter
Standard: 29.4 mm {1.16 in}
Minimum: 28.8 mm {1.13 in}

5.  Measure the segment groove depth of the commutator.

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•  If not within the minimum specification, undercut the grooves to the standard depth.
Segment groove depth of starter commutator
Standard: 0.5 mm {0.02 in}
Minimum: 0.2 mm {0.008 in}


Magnetic switch

1.  Inspect for continuity between terminals S and M using a tester.

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•  If there is no continuity, replace the magnetic switch.

2.  Inspect for continuity between terminal S and the body using a tester.

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•  If there is no continuity, replace the magnetic switch.

3.  Verify that there is no continuity between terminals M and B using a tester.

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•  If there is continuity, replace the magnetic switch.


Brush and brush holder

1.  Verify that there is no continuity between each insulated brush and plate using a tester.

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•  If there is continuity, replace the brush holder.

2.  Measure the brush length.

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•  If any brush is worn almost to or beyond the minimum specification, replace all of the brushes.
Starter brush length
Standard: 12.3 mm {0.484 in}
Minimum: 5.5 mm {0.22 in}

3.  Measure the brush spring force using a spring balance.

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•  If not within the minimum specification, replace the brush and brush holder component.
Starter brush spring force
Standard: 15.0—20.4 N {1.53—2.08 kgf, 3.38—4.58 lbf}
Minimum: 2.75 N {0.280 kgf, 0.618 lbf}