STARTER INSPECTION[ZJ, ZY, Z6]

id0119b1800300


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 or engine 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.

am3zzw00000225

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
90 A or less


Magnetic Switch Operation Inspection


Pull‐out test

Note
•  In case the battery is being charged, the pinion may turn during a protruded state. This is normal because the current flows to the motor through the pull‐in coil and the motor turns.

1.  Verify that the drive pinion is pulled out with battery positive voltage connected to terminal S and the starter body grounded.

am3zzw00002562

•  If not pulled out, 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.

am3zzw00002563

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

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


Pinion Gap Inspection

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

am3zzw00002564

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

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

am3zzw00002565

•  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 conductivity between the commutator and the core at each segment using an ohmmeter.

am3zzw00000959

•  If there is conductivity, replace the armature.

2.  Verify that there is no conductivity between the commutator and the shaft using an ohmmeter.

am3zzw00000960

•  If there is conductivity, replace the armature.

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

am3zzw00000961

Starter armature runout
0.1 mm {0.004 in} max.

4.  Measure the commutator diameter.

am3zzw00000962

•  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 commutator.

am3zzw00000963

•  If not within the minimum specification, undercut the grooves to the standard depth.
Segment groove depth of starter commutator
Standard: 0.5 mm {0.020 in}
Minimum: 0.2 mm {0.008 in}


Magnetic switch

1.  Inspect for conductivity between terminals S and M using an ohmmeter.

•  If there is no conductivity, replace the magnetic switch.
am3zzw00000964

2.  Inspect for conductivity between terminal S and the body using an ohmmeter.

•  If there is no conductivity, replace the magnetic switch.
am3zzw00000965

3.  Verify that there is no conductivity between terminals M and B using an ohmmeter.

•  If there is conductivity, replace the magnetic switch.
am3zzw00000966


Brush and brush holder

1.  Verify that there is no conductivity between each insulated brush and plate using an ohmmeter.

•  If there is conductivity, replace the brush holder.
am3zzw00000967

2.  Measure the brush length.

•  If any brush is worn almost to or beyond the minimum specification, replace all the brushes.
Starter brush length
Standard: 12.3 mm {0.48 in}
Minimum: 7.0 mm {0.28 in}
am3zzw00000970

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

•  If not within the minimum specification, replace the brush spring.
Starter brush spring force
Standard: 18.3—24.8 N {1.87—2.52 kgf, 4.12—5.57 lbf}
Minimum: 5.9 N {0.6 kgf, 1.3 lbf}
am3zzw00000969