7GR-FKS STARTING STARTER INSPECTION

Hide Display 28100 1.INSPECT STARTER ASSEMBLY

CAUTION:: As a large electric current passes through the cable during this inspection, a thick cable must be used. If not, the cable may become hot and cause injury.

NOTICE:: The following tests must be done within 3 to 5 seconds to prevent the coil from burning out.

a.

Mount the starter assembly in a vise between aluminum plates.

NOTICE:: Do not overtighten the vise.

b.

Perform a pull-in test.

i.

Remove the nut and disconnect the lead wire from terminal C.

ii.

0.615,0.24 0.74,0.24 0.74,0.24 1.26,0.677 true 0.427,1.719 0.542,1.719 0.542,1.719 0.969,1.51 true 0.406,0.156 0.563,0.333 0.156,0.177 10 false *a 0.219,1.625 0.375,1.802 0.156,0.177 10 false *b

*a	Terminal 50
*b	Terminal C

Connect the battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear extends.

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

c.

0.344,1.771 0.469,1.771 0.469,1.771 0.99,1.542 true 0.125,1.688 0.323,1.865 0.198,0.177 10 false *a

*a	Terminal C

Perform a holding test.

i.

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

If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

d.

Inspect the clutch pinion gear return.

i.

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

If the clutch pinion gear does not return, replace the magnet starter switch assembly.

e.

Perform an operation test without load.

i.

Connect the lead wire to terminal C with the nut.

Torque:: 5.9 N*m (60 kgf*cm, 52 in.*lbf)

ii.

0.531,0.302 0.656,0.302 0.656,0.302 0.969,0.625 true 1.677,1.688 1.563,1.688 1.563,1.688 1.365,0.792 true 1.771,1.604 1.927,1.781 0.156,0.177 10 false *a 0.302,0.229 0.458,0.406 0.156,0.177 10 false *b

*a	Terminal 50
*b	Terminal 30

Connect the battery and an ammeter to the starter assembly as shown in the illustration.

iii.

Check that the starter rotates smoothly and steadily while the pinion gear is extended. 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.

HINT:: Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

Hide Display 28150 2.INSPECT MAGNET STARTER SWITCH ASSEMBLY

a.

Inspect the pull-in coil.

i.

1.344,2.115 1.198,1.729 1.198,1.729 1.083,1.729 true 2.594,2.458 3.063,1.958 3.063,1.958 3.146,1.958 false 0.896,1.646 1.073,1.802 0.177,0.156 10 false *b 3.198,1.875 3.354,2.031 0.156,0.156 10 false *a

*a	Terminal 50
*b	Terminal C

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 - Terminal C	Always	Below 1 Ω

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

b.

Inspect the holding coil.

i.

2.021,1.771 1.771,0.729 1.771,0.729 1.635,0.729 true 2.615,2.469 3.073,1.875 3.073,1.875 3.156,1.875 true 3.198,1.781 3.385,1.948 0.188,0.167 10 false *a 1.417,0.656 1.615,0.833 0.198,0.177 10 false *b

*a	Terminal 50
*b	Switch Body

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 - Switch body	Always	Below 2 Ω

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

Hide Display 3.INSPECT BRUSH

a.

0.083,0.156 0.302,0.333 0.219,0.177 10 false *a 0.073,2.542 0.292,2.719 0.219,0.177 10 false *b 0.573,2.042 0.792,2.219 0.219,0.177 10 false *c 2.448,4.219 2.667,4.396 0.219,0.177 10 false *c

*a	Brush Holder Side
*b	Starter Yoke Side
*c	Length

Using a vernier caliper, measure the brush length.

Standard length:: 15.5 mm (0.610 in.)

Minimum length:: 8.5 mm (0.335 in.)

If the length is less than the minimum, replace the starter brush holder assembly and starter yoke assembly.

Hide Display 28140 4.INSPECT STARTER BRUSH HOLDER ASSEMBLY

a.

0.854,1.406 1.031,1.406 1.031,1.406 1.323,1.76 false 2.25,1.344 2.51,1.115 2.51,1.115 2.667,1.115 false 0.646,1.323 0.958,1.479 0.313,0.156 10 false *a 2.729,1.042 3.042,1.198 0.313,0.156 10 false *b

*a	Brush
*b	Brush Spring

Check the brush spring load.

i.

Take a pull scale reading immediately after the brush spring separates from the brush.

Standard spring load:: 17.6 to 23.5 N (1.8 to 2.4 kgf, 4.0 to 5.3 lbf)

Minimum spring load:: 11.8 N (1 kgf, 2.7 lbf)

If the spring load is less than the minimum, replace the starter brush holder assembly.

b.

Inspect the insulation.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Positive (+) brush holder - Negative (-) brush holder	Always	10 kΩ or higher

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

Hide Display 28120 5.INSPECT STARTER YOKE ASSEMBLY

a.

Inspect the field coil for an open circuit.

i.

0.521,0.542 0.938,0.542 true 2.375,0.656 2.375,0.323 2.375,0.323 2.542,0.323 false 1.167,2 1.333,2 1.333,2 1.583,1.583 true 0.333,0.448 0.646,0.646 0.313,0.198 10 false *a 2.594,0.229 2.906,0.427 0.313,0.198 10 false *b 0.969,1.906 1.281,2.104 0.313,0.198 10 false *c

*a	Lead Wire
*b	Brush
*c	Starter Yoke Body

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Lead wire - Brush	Always	Below 1 Ω
Starter yoke body - Brush	Always	10 kΩ or higher

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

Hide Display 28160 6.INSPECT STARTER ARMATURE ASSEMBLY

a.

Check the commutator for dirt and/or burns on the surface.

If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. If necessary, replace the starter armature assembly.

b.

Inspect the commutator for an open circuit.

i.

0.362,1.023 0.545,1.199 0.184,0.176 10 *a 1.196,1.559 0.739,1.128 0.739,1.128 0.578,1.128 false

*a

Segment

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Segment - Segment	Always	Below 1 Ω

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

c.

Inspect the commutator for a short circuit.

i.

2.384,0.454 2.578,0.634 0.194,0.180 10 *b 0.328,1.03 0.522,1.192 0.194,0.162 10 *a 1.195,1.554 0.685,1.13 0.685,1.13 0.55,1.13 false 1.974,1.249 2.24,0.549 2.24,0.549 2.364,0.549 false

*a	Segment
*b	Coil Core

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Segment - Coil core	Always	10 kΩ or higher

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

d.

Check the commutator circle runout.

i.

Place the bearing of armature on V-blocks.

ii.

Using a dial indicator, measure the circle runout.

Maximum runout:: 0.05 mm (0.00197 in.)

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

e.

Using a vernier caliper, measure the commutator diameter.

Standard diameter:: 30.0 mm (1.18 in.)

Minimum diameter:: 29.0 mm (1.14 in.)

If the diameter is less than the minimum, replace the starter armature assembly.

f.

Using a vernier caliper, measure the undercut depth of the commutator.

Standard undercut depth:: 0.6 mm (0.0236 in.)

Minimum undercut depth:: 0.2 mm (0.00787 in.)

If the undercut depth is less than the minimum, replace the starter armature assembly.

Hide Display 28011 7.INSPECT STARTER CLUTCH SUB-ASSEMBLY

a.

0,0 0,0 false

	Free
	Lock

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

If the result is not as specified, replace the starter clutch sub-assembly.

b.

Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.

7GR-FKS STARTING STARTER INSPECTION

PROCEDURE