Starter Motor: Testing and Inspection

2GR-FE STARTING: STARTER: INSPECTION

INSPECTION

1. INSPECT STARTER ASSEMBLY
CAUTION:
Make sure to complete each of the following tests within 5 seconds to prevent the coil from burning out.

(a) Perform 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 moves outward.
If the clutch pinion gear does not move outward, replace the repair service starter kit.
(b) Perform hold-in test:




(1) Disconnect the negative (-) terminal lead from terminal C under the conditions for pull-in test. Check that the pinion gear remains out.
If the clutch pinion gear moves inward, replace the repair service starter kit.
(c) Inspect clutch pinion gear return:




(1) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear moves inward.
If the clutch pinion gear does not move inward, replace the repair service starter kit.
(d) Perform no-load performance test:
(1) Connect the field coil 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 specified current.
Specified current:






If the result is not as specified, overhaul the starter assembly.
2. INSPECT MAGNETIC SWITCH ASSEMBLY
(a) Check the plunger.




(1) Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the magnetic switch assembly.
(b) Inspect the resistance of the pull-in coil.




(1) Using an ohmmeter, measure the resistance between terminals 50 and C.
Standard resistance:






If the resistance is not as specified, replace the magnetic switch assembly.
(c) Inspect the resistance of the hold-in coil.




(1) Using an ohmmeter, measure the resistance between terminal 50 and switch body.
Standard resistance:






If the resistance is not as specified, replace the magnetic switch assembly.
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) Inspect the resistance of the commutator.




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






If the resistance is not as specified, replace the starter armature assembly.




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






If the resistance is not as specified, replace the starter armature assembly.





(c) Using vernier calipers, measure the commutator depth.
Specified depth:
3.1 mm (0.122 in.)
Maximum depth:
3.8 mm (0.150 in.)
If the depth is greater than the maximum, replace the starter armature assembly.
4. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
(a) Check the brush length.




(1) Using vernier calipers, measure the brush length.
Specified length:
9.0 mm (0.354 in.)
Maximum length:
4.0 mm (0.157 in.)
If the length is less than the minimum, replace the starter commutator end frame assembly.
(b) Check the resistance.




(1) Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
Resistance:
10 kOhms or higher
If the resistance is not as specified, repair or replace the starter commutator end frame assembly.
5. INSPECT STARTER CLUTCH
(a) Check the starter clutch.




(1) 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 starter drive housing assembly.