Starter Motor: Testing and Inspection
STARTER INSPECTION[L3, AJ]On-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 transaxle 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: Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.
1. Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded.
- If the starter motor pinion is not extended, 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 it does not return, repair or replace the starter.
Pinion Gap Inspection
1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded.
CAUTION: Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s.
2. Measure the pinion gap while the drive pinion is extended.
- If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).
Specification
L3: 0.5-2.0 mm {0.02-0.08 in}
AJ: 0 mm {0 in}
Starter Inner Parts Inspection
Armature
1. Verity that there is no continuity between the commutator and the core at each segment using a tester.
- If there is continuity, replace the armature.
2. Verify that there is no continuity between the commutator and the shaft using a tester.
- If there is continuity, replace the armature.
3. Place the armature on V-blocks, and measure the runout using a dial indicator.
Maximum runout
L3: 0.05 mm {0.002 in}
AJ MTX: 0.1 mm {0.004 in}
AJ ATX: 0.05 mm {0.002 in}
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 the commutator.
- If not within the minimum specification, undercut the grooves to the standard depth.
Standard depth
L3: 0.4-0.6 mm {0.016-0.023 in}
AJ MTX: 0.5 mm {0.02 in}
AJ ATX: 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 a tester.
- If there is no continuity, replace the magnetic switch.
2. Inspect for continuity between terminal S and the body using a tester.
- If there is no continuity, replace the magnetic switch.
3. Verify that there is no continuity between terminals M and B using a tester.
- 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 a tester.
- 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 of 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 and brush holder component.
Standard spring force
L3: 21.6 N {2.20 kgf, 4.84 lbf}
AJ MTX: 18.3-24.8 N {1.87-2.52 kgf, 4.42-5.57 lbf}
AJ ATX: 21.6 N {2.20 kgf, 4.84 lbf}
Minimum spring force 5.9 N {0.6 kgf, 1.3 lbf}