Starter Motor: Testing and Inspection

2GR-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
NOTE: These tests must be performed within 5 seconds to prevent the coil from burning out.

(a) Perform the pull-in test.
(1) Disconnect the lead wire from terminal C.




(2) Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear extends.
If the clutch pinion gear does not move, replace the repair service starter kit.





(b) Perform the hold-in test.
(1) Maintain the battery connections of the pull-in test above, but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.
If the clutch pinion gear returns inward, replace the repair service starter kit.





(c) Perform the clutch pinion gear return test.
(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns.
If the clutch pinion gear does not return, replace the repair service starter kit.





(d) Perform the no-load performance test.
(1) Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(2) Clamp the starter in a vise.
(3) Connect the battery and an ammeter to the starter as shown in the illustration.
(4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the current specified below.
Standard current:






If the result is not as specified, overhaul the starter assembly.
2. INSPECT REPAIR SERVICE STARTER KIT





(a) Check the plunger.
(1) Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the repair service starter kit.





(b) Check if the pull-in coil has an open circuit.
(1) Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard resistance:






If the result is not as specified, replace the repair service starter kit.





(c) Check if the hold-in coil has an open circuit.
(1) Using an ohmmeter, measure the resistance between terminal 50 and the switch body.
Standard resistance:






If the result is not as specified, replace the repair service starter kit.
3. INSPECT STARTER ARMATURE ASSEMBLY
(a) Check the commutator surface for dirt or burning.
If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.
(b) Check if the commutator has an open circuit.




(1) Using an ohmmeter, measure the resistance between any 2 segments of the commutator.
Standard resistance:






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




(2) Using an ohmmeter measure the resistance between each segment of the commutator and armature coil core.
Standard resistance:






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





(c) Using a vernier caliper, measure the commutator's length.
Standard length:
3.1 to 3.8 mm (0.122 to 0.150 in.)
If the length is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY





(a) Using a vernier caliper, measure the brush length.
Standard length:
4.0 to 9.0 mm (0.158 to 0.354 in.)
If the length is less than the minimum, replace the starter commutator end frame assembly.





(b) Check the brush insulation.
(1) Using a ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
Standard resistance:






If the result is not as specified, repair or replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH





(a) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
If necessary, replace the motor terminal starter kit.