M20C-FKS, M20D-FKS STARTING STARTER(for 1.2 kW Type) 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.

Once again, install and fasten the removed nut to the terminal M.

HINT:: Make sure the contact area of the terminal M is not floating.

iii.

1.292,0.948 1.302,1.833 true 2.635,1.823 2.927,1.823 false 0.906,0.396 1.104,0.396 1.104,0.396 1.26,0.635 false 0.74,0.302 1.052,0.5 0.313,0.198 10 false *b 2.99,1.74 3.302,1.938 0.313,0.198 10 false *a 1.177,1.833 1.49,2.031 0.313,0.198 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.

1.281,0.958 1.313,1.875 true 0.917,0.438 1.104,0.438 1.104,0.438 1.229,0.625 false 2.635,1.802 2.969,1.802 false 1.219,1.854 1.531,2.052 0.313,0.198 10 false *c 0.74,0.344 1.052,0.542 0.313,0.198 10 false *b 3.01,1.688 3.323,1.885 0.313,0.198 10 false *a

*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.

2.625,1.802 2.917,1.802 false 0.854,0.375 1.063,0.375 1.063,0.375 1.24,0.656 false 2.948,1.698 3.26,1.896 0.313,0.198 10 false *a 0.688,0.281 1,0.479 0.313,0.198 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.

2.646,1.813 2.917,1.813 false 0.823,0.542 1.021,0.542 1.021,0.542 1.094,0.698 false 1.26,0.646 1.417,0.208 1.417,0.208 1.667,0.208 true 2.948,1.708 3.26,1.906 0.313,0.198 10 false *a 1.698,0.125 2.01,0.323 0.313,0.198 10 false *c 0.688,0.458 1,0.656 0.313,0.198 10 false *b

*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 90 A

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

Hide Display 28160 2.INSPECT STARTER ARMATURE ASSEMBLY

a.

2.26,1.167 2.885,1.094 2.885,1.094 2.354,0.958 false 2.917,1.021 3.229,1.219 0.313,0.198 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.

b.

0.792,1.302 1.073,1.302 1.073,1.302 1.604,0.896 false 2.302,1.198 2.615,0.542 2.615,0.542 2.833,0.542 true 2.885,0.458 3.198,0.656 0.313,0.198 10 false *a 0.563,1.219 0.875,1.417 0.313,0.198 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.

c.

Check the commutator appearance.

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

d.

0.365,0.635 0.552,0.635 0.552,0.635 0.875,0.833 false 2.052,1.417 2.604,1.698 2.604,1.698 2.823,1.698 true 0.208,0.542 0.427,0.698 0.219,0.156 10 false *a 2.844,1.604 3.063,1.76 0.219,0.156 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 greater 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:: 25 mm (0.984 in.)

Minimum Diameter:: 24 mm (0.945 in.)

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

f.

2.667,0.479 2.979,0.635 0.313,0.156 10 false *a

*a	Undercut Depth

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:: 0.2 mm (0.00787 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.

2.792,0.688 3.104,0.844 0.313,0.156 10 false *a

*a

Length

Check the brush length.

i.

Using a vernier caliper, measure the brush length.

Standard Length:: 11.6 mm (0.457 in.)

Minimum Length:: 7.6 mm (0.299 in.)

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

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

a.

Install the starter armature assembly to the starter center bearing clutch sub-assembly.

b.

2.042,0.646 2.208,0.802 0.167,0.156 10 false *a 2,1.74 2.156,1.906 0.156,0.167 10 true *b

*a	Free
*b	Lock

Hold the starter armature 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.

2.052,1.25 2.719,1.25 false 2.198,0.573 2.385,0.146 2.385,0.146 2.813,0.146 true 2.854,0.052 3.167,0.208 0.313,0.156 10 false *a 2.76,1.188 3.073,1.344 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.

0.479,0.323 0.229,0.323 0.229,0.323 0.563,0.979 false 2.24,0.563 2.573,0.24 2.573,0.24 2.854,0.24 true 2.906,0.156 3.219,0.313 0.313,0.156 10 false *a 0.521,0.25 0.833,0.406 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.

M20C-FKS, M20D-FKS STARTING STARTER(for 1.2 kW Type) INSPECTION

PROCEDURE