Starter Motor: Testing and Inspection

2GR-FE STARTING: STARTER: INSPECTION

1. INSPECT STARTER ASSEMBLY

NOTICE:
These tests must be performed within 3 to 5 seconds to avoid burning out the coil.

(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 on the left. Check that the clutch pinion gear extends.

If the clutch pinion gear does not move, replace the magnetic switch.

(b) Perform the hold-in test.





(1) Maintain the battery connections in step (a), but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended.

If the clutch pinion gear returns inward, replace the magnetic switch.

(c) Check the clutch pinion gear return.





(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 magnetic switch.

(d) Perform the no-load performance test.





(1) Connect the lead wire to terminal C. Make sure that the lead is not grounded.

(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:

90 A or less at 11.5V

If the result is not as specified, replace 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 the resistance.





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

Resistance:

below 1 Ohms

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

(c) Using an ohmmeter, measure the resistance between terminal 50 and the starter kit body.





Resistance:

below 2 Ohms

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

3. INSPECT STARTER ARMATURE ASSEMBLY

(a) Check the resistance.





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

Resistance:

below 1 Ohms

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

(b) Using an ohmmeter, measure the resistance between the segment of the commutator and armature coil core.





Resistance:

10 kOhms or higher

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

(c) Check the commutator surface for dirt or burning.

If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or leather.

(d) Check the commutator depth.





(1) Using vernier calipers, measure the commutator depth.

Standard depth:

3.1 mm (0.122 in.)

Maximum depth:

3.8 mm (0.150 in.)

If the length 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.

Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.158 in.)

If the length is less than minimum, replace the starter commutator end frame.

(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.

5. INSPECT MOTOR TERMINAL STARTER KIT

(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. Check that it locks.

If necessary, replace the motor terminal starter kit.