Starter Motor: Testing and Inspection

2GR-FSE STARTING: STARTER: INSPECTION

1. INSPECT STARTER ASSEMBLY

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

(a) Perform pull-in/holding test.

(1) Disconnect the lead wire from terminal C.

(2) Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.





If the result is not as specified, replace the magnet starter switch assembly.

(3) Disconnect the negative (-) lead from terminal C under condition pull-in test. Check that the pinion gear remains out.





If the result is not as specified, replace the magnet starter switch assembly.

(4) Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.





If the result is not as specified, replace the magnet starter switch assembly.

(b) Perform operation test without load.

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(2) Mount 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 while the pinion gear is moving outward. Then measure the current.

Standard current:

90 A or less at 11.5 V





If the result is not as specified, overhaul the starter.

2. INSPECT STARTER ARMATURE ASSEMBLY

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





Standard resistance:

Below 1 Ohms

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

(b) Measure the resistance between each segment of the commutator and armature coil core.





Standard resistance:

10 kOhms or higher

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

(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) Using a vernier caliper, measure the depth indicated in the illustration.





Standard 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 armature assembly.

3. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY

(a) Using a vernier caliper, 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 the minimum, replace the starter commutator end frame assembly.

(b) Measure the resistance between the positive (+) and negative (-) brush holders.





Standard resistance:

10 kOhms or higher

If the result is not as specified, replace the starter commutator end frame assembly.

4. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY

(a) Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

If damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

(b) Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.





If necessary, replace the center bearing clutch sub-assembly.

5. INSPECT REPAIR SERVICE STARTER KIT

(a) Check the operation.





(1) Push in the plunger, and then 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.





Standard resistance:

Below 1 Ohms

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

(2) Measure the resistance between terminal 50 and the switch body.





Standard resistance:

Below 2 Ohms

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