Starter (for Cold Area)
1GR-FE STARTING: STARTER (for Cold Area): INSPECTION
INSPECTION
1. INSPECT STARTER ASSEMBLY
NOTE: These tests must be done within 3 to 5 seconds to avoid burning out the coil.
(a) Do pull-in test (Condition A).
(1) Disconnect the field coil lead wire from terminal C.
(2) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear protrudes.
(b) Do holding test.
(1) Disconnect the negative (-) lead from the terminal C with the above condition A is being sustained.
Check that the pinion gear remains protruded.
(c) Inspect clutch pinion gear return.
(1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward.
(d) Perform the operation test without load.
(1) Connect the field coil lead wire to terminal C.
for standard area - Torque: 10 Nm (102 kgf-cm, 89 ft-lbf)
for cold area - Torque: 5.9 Nm (60 kgf-cm, 52 in-lbf)
(2) Hold the starter with a vise.
(3) Connect the battery and ammeter to the starter as shown.
(4) Check that the ammeter indicates the specified current.
Specified current (for standard area):
90 A or less at 11.5V
Specified current (for cold area)
100 A or less at 11.5 V
2. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check the commutator for open circuit.
(1) Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segment, replace the armature.
(b) Check the commutator for ground.
(1) Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty and burn on surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
(d) Check for the commutator 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 maximum, correct it on a lathe.
(e) Using vernier calipers, measure the commutator diameter.
Standard diameter:
35.0 mm (1.378 in.)
Maximum diameter
34.0 mm (1.339 in.)
If the diameter is less than minimum, replace the armature.
(f) Check that the undercut depth is clean and free of foreign objects. Smooth out the edge.
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 minimum, correct it with a hacksaw blade.
3. INSPECT STARTER YOKE ASSEMBLY
(a) Check the starter yoke for open circuit.
(1) Using an ohmmeter, check that there is continuity between the lead wire and brushes.
If there is no continuity, replace the starter yoke.
(b) Check the shunt coil for open circuit.
(1) Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B).
Standard resistance:
1.5 to 1.9 Ohms at 20°C (68°F)
If the resistance is not as specified, replace the starter yoke.
4. INSPECT BRUSH
(a) Check the brushes 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 minimum, replace the brush holder and starter yoke.
5. INSPECT STARTER BRUSH HOLDER ASSEMBLY
(a) Check the brush holder insulation.
(1) Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
(b) Check the brush spring load.
(1) Take a pull scale reading at the instant 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.
6. INSPECT STARTER CLUTCH SUB-ASSEMBLY
(a) Check the clutch pinion gear.
(1) Hold the starter clutch and 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.
7. INSPECT MAGNET STARTER SWITCH ASSEMBLY
(a) Check the pull-in coil for open circuit.
(1) Using an ohmmeter, check that there is continuity between terminal 50 and C.
If there is no continuity, replace the magnet starter switch.
(b) Check the holding coil for open circuit.
(1) Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, replace the magnet starter switch.