Starter Motor: Testing and Inspection

2AR-FE STARTING: STARTER: INSPECTION

1. INSPECT STARTER ASSEMBLY

CAUTION:
As a large electric current passes through the cable during this inspection, a thick cable must be used.

Otherwise, the cable may become hot and cause injury.

NOTICE:
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

(a) Mount the starter in a vise between aluminum plates.

NOTICE:
Ensure that the starter is secured firmly in the vise to prevent it from falling out.

(b) Perform a pull-in test.

(1) Remove the nut and disconnect the lead wire from terminal C.





(2) Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear moves outward.





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If the clutch pinion gear does not move outward, replace the magnetic switch assembly.

(c) Perform a holding test.

(1) Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.





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If the clutch pinion gear moves inward, replace the magnetic switch assembly.

(d) Inspect the clutch pinion gear return.

(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.





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If the clutch pinion gear does not move inward, replace the magnet switch assembly.

(e) Perform an operation test without load.

(1) Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(2) Connect the battery and an ammeter to the starter as shown in the illustration.





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NOTICE:
Do not allow any leads to get caught as the pinion gear operates.

(3) 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 MAGNETIC SWITCH ASSEMBLY

(a) Check the plunger.

(1) Push in the plunger and check that it returns quickly to its original position.





If necessary, replace the magnetic switch assembly.

(b) Inspect the resistance of the pull-in coil.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





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If the result is not as specified, replace the magnetic switch assembly.

(c) Inspect the resistance of the holding coil.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





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If the result is not as specified, replace the magnetic switch assembly.

3. INSPECT STARTER ARMATURE ASSEMBLY

HINT
If there is no continuity between any segments, replace the starter armature assembly.

(a) Check the commutator for contamination and burns on its surface.

If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

(b) Check the commutator.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





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If the result is not as specified, replace the starter armature assembly.

(c) Check the commutator.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





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If the result is not as specified, replace the starter armature assembly.

(d) Using a vernier caliper, measure the commutator length.





Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

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If the length is more than the maximum, replace the starter armature assembly.

4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Check the brush length.

(1) Using a vernier caliper, measure the brush length.





Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.157 in.)

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If the length is less than the minimum, replace the starter commutator end frame assembly.

(b) Check the resistance.

(1) Measure the resistance according to the value(s) in the table below.





Standard Resistance:





If the result is not as specified, replace the starter commutator end frame assembly.

5. INSPECT MOTOR TERMINAL STARTER KIT

(a) Check the starter clutch.

(1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.





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If necessary, replace the starter drive housing assembly.