Starter Motor: Testing and Inspection
STARTER INSPECTIONOn-vehicle Inspection
1. Verify that the battery is fully charged.
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
- If the starter does not operate, inspect the following:
- Remove the starter, and inspect the starter unit.
- Inspect the related wiring harnesses, the ignition switch, and the transmission range switch (ATX).
No-load test
1. Verify that the battery is fully charged.
2. Connect the starter, battery; and a tester as shown in the figure.
3. Operate the starter and verify that it rotates smoothly.
- If the starter does not rotate smoothly, inspect the starter unit.
4. Measure the voltage and current while the starter is operating.
- If not within the specification, replace the starter
Magnetic Switch Operation Inspection
Pull-out test
NOTE: In case the battery is being charged, the pinion may turn during a protruded state. This is normal because the current flows to the motor through the pull-in coil and the motor turns.
1. Verify that the drive pinion is pulled out with battery positive voltage connected to terminal S and the starter body grounded.
- If not pulled out, repair or replace the starter.
Return test
1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M and ground the starter body.
3. Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.
- If does not return, repair or replace the starter.
Pinion Gap Inspection
1. Pull out the drive pinion with battery positive voltage connected to terminal S and the starter body grounded.
CAUTION: Applying power for more than 105 can damage the starter. Do not apply power for more than the aforementioned time.
2. Measure the pinion gap while the drive pinion is pulled.
- If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).
Pinion gap
0.5-2.0 mm {0.02-0.07 in}
Starter inner Parts inspection Armature
1. Verify that there is no continuity between the commutator and the core at each segment using an ohmmeter.
- If there is continuity, replace the armature.
2. Verify that there is no continuity between the commutator and the shaft using an ohmmeter.
- If there is continuity, replace the armature.
3. Place the armature on V~blocks, and measure the runout using a dial indicator.
Runout
0.05 mm {0.002 in} max.
4. Measure the commutator diameter.
- If not within the minimum specification, replace the armature.
Standard commutator diameter
29.4 mm {1.16 in}
Minimum commutator diameter
28.8 mm {1.13 in}
5. Measure the segment groove depth of commutator.
- If not within the minimum specification, undercut the grooves to the standard depth.
Standard depth
0.4-0.6 mm {0.016-0.023 in}
Minimum depth
0.2 mm {0.008 in}
Magnetic switch
1. Inspect for continuity between terminals S and M using an ohmmeter.
- If there is no continuity, replace the magnetic switch.
2. Inspect for continuity between terminal S and the body using an ohmmeter.
- If there is no continuity, replace the magnetic switch.
3. Verify that there is no continuity between terminals M and B using an ohmmeter.
- If there is continuity, replace the magnetic switch.
Brush and brush holder
1. Verify that there is no continuity between each insulated brush and plate using an ohmmeter.
- If there is continuity. replace the brush holder.
2. Measure the brush length.
- If any brush is worn almost to or beyond the minimum specification, replace all the brushes.
Standard brush length
12.3 mm {0.48 in}
Minimum brush length
7.0 mm {0.28 in}
3. Measure the brush spring force using a spring balance.
- If not within the minimum specification, replace the brush spring.
Standard spring force
18.3-24.9 N {1.87-2.53 kgf, 4.12-5.59 lbf}
Minimum spring force
5.9 N {0.6 kgf, 1.3 lbf}