Starter Motor: Testing and Inspection
TESTNOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil.
1. DO PULL-IN TEST
a. Disconnect the field coil lead wire from terminal C.
b. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
a. Connect the battery and ammeter to the starter as shown.
b. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter reads the specified current.
Specified current:
1.4 kW type: At 11.5 V: 90 A or less
1.8 kW, 2.0 kW type: At 11.5 V: 100 A or less
INSPECTION
1. INSPECT ARMATURE COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segment, replace the armature.
2. INSPECT ARMATURE COIL FOR GROUNDED
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400) or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
a. Place the commutator on V-blocks.
b. Using a dial indicator, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.4 kW type: 30 mm (1.180 in.)
1.8 kW type: 35 mm (1.378 in.)
Minimum diameter:
1.4 kW type: 29 mm (1.140 in.)
1.8 kW type: 34 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign material. Smooth out the edge.
Standard undercut depth:
1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW type: 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a hacksaw blade.
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. (1.4 kW type)
INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. (1.8 kW type)
INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between terminal (A) and (B).
Standard resistance: At 20°C (68°F): 1.4 - 1.9 ohms
If the resistance is not as specified, repair or replace the field frame.
10.INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and field frame.
11. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring separates from the brush.
Standard installed load:
1.4 kW type: 17.6 - 23.5 N (1.80 - 2.40 kg, 4.0 - 5.3 lb)
1.8 kW type: 21.5 - 27.5 N (2.20 - 2.80 kg, 4.9 - 6.2 lb)
Minimum installed load:
1.4 kW type: 11.8 N (1.20 kg, 2.6 lb)
1.8 kW type: 12.7 N (1.30 kg, 2.7 lb)
If the installed load is less than minimum, replace the brush springs.
HINT: Take the pull scale reading the instant the brush spring separates from the brush.
12. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
13. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for wear or damage.
14. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion counterclockwise and check that it locks. If necessary, replace the clutch assembly.
15. INSPECT FRONT BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. IF NECESSARY, REPLACE FRONT BEARING
a. Using SSI remove the bearing.
SST 09286-46011
b. Using a press, press in a new front bearing.
17. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
18. IF NECESSARY, REPLACE REAR BEARING
a. Using SST remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new rear bearing.
NOTE: Be careful of the bearing installation direction.
SST 09201-41020
19. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.
20. DO HOLD-IN COIL CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, check and replace the magnetic switch.