Starter (for 2WD and Pre-Runner)
1GR-FE STARTING: STARTER (for 2WD and Pre-Runner): INSPECTION
1. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check the commutator for an open circuit.
(1) Using an ohmmeter, measure the resistance between the segments of the commutator.
Standard:
1 Ohms or lower
If the result is not as specified, replace the starter armature.
(b) Check the commutator for ground.
(1) Using an ohmmeter, measure the resistance between the commutator and armature coil core.
Standard:
10 kOhms or higher
If the result is not as specified, replace the starter armature.
(c) Check whether the commutator surface is dirty or burnt.
If necessary, clean it with sandpaper (No. 400) or a lathe.
(d) Check the commutator for runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the runout.
Maximum runout:
0.05 mm (0.0020 in.)
If the runout is greater than the maximum, correct it on a lathe.
(e) Using vernier calipers, measure the commutator diameter.
Standard diameter:
35.0 mm (1.378 in.)
Minimum diameter:
34.0 mm (1.339 in.)
If the diameter is less than the minimum, replace the armature.
(f) Check that the undercut portion between the segments is free of foreign objects. Measure its depth.
Standard undercut depth:
0.7 mm (0.028 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than the minimum, correct it with a hacksaw blade.
2. INSPECT STARTER YOKE ASSEMBLY
(a) Check the starter yoke for an open circuit.
(1) Using an ohmmeter, measure the resistance between the lead wire and brushes.
Standard:
1 Ohms or lower
If the result is not as specified, replace the starter yoke.
(b) Check the shunt coil for an open circuit.
(1) Using an ohmmeter, measure the resistance between shunt coil terminals A and B.
Standard:
1.5 to 1.9 Ohms at 20°C (68°F)
If the result is not as specified, replace the starter yoke.
3. INSPECT BRUSH
(a) Check the brush length.
(1) Using vernier calipers, measure the brush length.
Standard length:
15.0 mm (0.591 in.)
Minimum length:
9.0 mm (0.354 in.)
If the length is less than the minimum, replace the brush holder and starter yoke.
4. INSPECT STARTER BRUSH HOLDER ASSEMBLY
(a) Check the blush holder insulation.
(1) Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.
Standard:
10 kOhms or higher
If the result is not as specified, replace the brush holder.
(b) Check the brush spring load.
(1) Take the pull scale reading as soon as the brush spring separates from the brush.
Standard spring load:
21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf)
Minimum spring load:
12.7 N (1.3 kgf, 2.9 lbf)
If the spring load is less than the minimum, replace the brush holder.
5. INSPECT STARTER CLUTCH SUB-ASSEMBLY
(a) Check the clutch pinion gear.
(1) Hold the starter clutch, rotate the pinion gear clockwise and check that it turns freely.
(2) Try to rotate the pinion gear counterclockwise and check that it locks.
If necessary, replace the starter clutch.
6. INSPECT MAGNET STARTER SWITCH ASSEMBLY
(a) Check the pull-in coil for an open circuit.
(1) Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard:
1 Ohms or lower
If the result is not as specified, replace the magnet starter switch.
(b) Check the holding coil for an open circuit.
(1) Using an ohmmeter, measure the resistance between terminal 50 and the switch body.
Standard:
2 Ohms or lower
If the result is not as specified, replace the magnet starter switch.