M20D-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:: Perform each of the following tests within 3 to 5 seconds to prevent the coil from burning out.

a.

Perform a pull-in test.

i.

Remove the nut, and disconnect the lead wire from terminal M.

ii.

1.208,0.688 1.438,0.688 true 2.844,2.99 2.844,2.688 false 1.49,2.906 1.49,1.906 true 2.781,2.99 3.094,3.146 0.313,0.156 10 false *a 1.042,0.583 1.354,0.74 0.313,0.156 10 false *b 1.438,2.906 1.781,3.083 0.344,0.177 10 false *c

*a	Starter Body
*b	Terminal 50
*c	Terminal C
	Moves outward

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

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

b.

Perform a hold-in test.

i.

1.219,0.688 1.427,0.688 true 1.479,2.865 1.479,1.896 true 2.854,3.021 2.854,2.688 false 2.781,3.021 3.094,3.177 0.313,0.156 10 false *a 1.063,0.583 1.375,0.74 0.313,0.156 10 false *b 1.417,2.875 1.729,3.031 0.313,0.156 10 false *c

*a	Starter Body
*b	Terminal 50
*c	Terminal C
	Disconnect

While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

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

c.

Perform a return test.

i.

1.167,0.677 1.417,0.677 true 2.875,3.031 2.875,2.688 false 2.823,3.063 3.135,3.219 0.313,0.156 10 false *a 1.01,0.583 1.323,0.74 0.313,0.156 10 false *b

*a	Starter Body
*b	Terminal 50
	Disconnect
	Returns inward

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

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

d.

Perform a no-load performance test.

i.

Connect the lead wire to terminal M with the nut. Make sure that the lead wire is not grounded.

Torque:: 9.0 N*m (92 kgf*cm, 80 in.*lbf)

ii.

Secure the starter assembly in a vise between aluminum plates.

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

iii.

1.177,0.688 1.417,0.688 true 2.865,3.01 2.865,2.677 false 0.844,2.104 1.094,2.104 1.094,2.104 1.313,1.74 true 2.792,3.01 3.104,3.167 0.313,0.156 10 false *a 0.688,2 1,2.156 0.313,0.156 10 false *b 1.021,0.573 1.333,0.729 0.313,0.156 10 false *c

*a	Starter Body
*b	Terminal 30
*c	Terminal 50
	Rotates

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

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

iv.

Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.

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

Standard Current:

Tester Connection	Condition	Specified Condition
Battery positive (+) terminal - Terminal 30 - Terminal 50	11.5 V	Below 100 A

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

Hide Display 28160 2.INSPECT STARTER ARMATURE ASSEMBLY

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

a.

Check the commutator appearance.

If the surface is dirty or burnt, replace the stater armature assembly.

b.

2.177,0.917 2.635,0.917 2.635,0.917 2.01,1.094 true 2.698,0.802 3.01,0.958 0.313,0.156 10 false *a

*a

Segment

Check the commutator for an open circuit.

i.

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.

0.729,1.469 0.885,1.469 0.885,1.469 1.25,1.052 true 2.25,1.115 2.771,0.833 2.771,0.833 2.948,0.833 true 3,0.719 3.313,0.875 0.313,0.156 10 false *a 0.552,1.365 0.865,1.521 0.313,0.156 10 false *b

*a	Segment
*b	Starter Armature Core

Check the commutator for a short circuit.

i.

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

Standard Resistance:

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

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

d.

0.5,0.604 0.708,0.604 0.708,0.604 0.979,0.885 true 2.083,1.406 2.698,1.406 true 0.354,0.5 0.667,0.656 0.313,0.156 10 false *a 2.75,1.292 3.063,1.448 0.313,0.156 10 false *a

*a	Armature Shaft

Check the commutator for runout.

i.

Place the armature shaft on V-blocks.

ii.

Using a dial indicator, measure the runout.

Maximum Runout:: 0.05 mm (0.00197 in.)

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

e.

0.167,0.063 0.479,0.219 0.313,0.156 10 false *a

*a

Diameter

Using a vernier caliper, measure the commutator diameter.

Standard Diameter (convex part):: 29 mm (1.14 in.)

Minimum Diameter (convex part):: 28 mm (1.10 in.)

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

f.

Check that the undercut portion between the segments is free of foreign matter and measure its depth.

Standard Undercut Depth:: 0.7 mm (0.0276 in.)

Minimum Undercut Depth:: 0.4 mm (0.0157 in.)

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

Hide Display 28140 3.INSPECT STARTER BRUSH HOLDER ASSEMBLY

a.

2.74,0.219 3.052,0.375 0.313,0.156 10 *a

*a

Length

Check the brush length.

i.

Using a vernier caliper, measure the brush length.

Standard Length (convex part):: 14.4 mm (0.567 in.)

Minimum Length (convex part):: 9.0 mm (0.354 in.)

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

b.

0.406,1.146 1.01,1.146 false 0.677,2.021 0.875,2.021 0.875,2.021 1.385,1.792 false 2.135,0.521 2.406,0.156 2.406,0.156 2.563,0.156 false 2.5,1.146 2.938,1.146 false 0.271,1.042 0.427,1.24 0.156,0.198 10 false A 0.552,1.927 0.708,2.125 0.156,0.198 10 false B 2.604,0.063 2.76,0.26 0.156,0.198 10 false D 2.99,1.042 3.146,1.24 0.156,0.198 10 false C

Check the brush holder resistance.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
A - B A - C B - D C - D	Always	10 kΩ or higher
A - D B - C	Always	Below 1 Ω

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

c.

Check the brush spring load.

i.

Take a pull scale reading the instant the brush spring separates from the brush.

Standard Spring Load:: 22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)

Minimum Spring Load:: 13.8 N (1.41 kgf, 3.1 lbf)

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

Hide Display 28021 4.INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

1.433,0.355 1.652,0.503 0.219,0.148 10 *a 1.253,1.592 1.482,1.736 0.229,0.144 10 *b

*a	Free
*b	Lock

a.

Check the clutch pinion gear.

i.

While holding the starter center bearing clutch sub-assembly, rotate the clutch pinion gear clockwise, and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

Hide Display 28150 5.INSPECT MAGNET STARTER SWITCH ASSEMBLY

a.

Check the plunger.

i.

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

If the plunger does not operate as specified, replace the magnet starter switch assembly.

b.

0.656,1.385 1.323,1.385 true 2.042,1.531 2.229,1.104 2.229,1.104 2.656,1.104 true 0.479,1.302 0.792,1.458 0.313,0.156 10 false *a 2.708,1.031 3.021,1.188 0.313,0.156 10 false *b

*a	Terminal 50
*b	Terminal C

Check the pull-in coil for an open circuit.

i.

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.

c.

0.552,1.385 1.313,1.385 true 0.74,0.208 1.802,0.208 true 0.375,1.313 0.688,1.469 0.313,0.156 10 false *a 0.573,0.135 0.885,0.292 0.313,0.156 10 false *b

*a	Terminal 50
*b	Magnet Starter Switch Assembly Body

Check the holding coil for an open circuit.

i.

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

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal 50 -Magnet starter switch assembly body	Always	Below 2 Ω

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

M20D-FKS STARTING STARTER INSPECTION

PROCEDURE