Starting System: Starter: Inspection

INSPECT 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.
  
  Fig 1: Checking Continuity Between Segments Of Commutator Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 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.
  
  Fig 2: Checking Continuity Between Commutator & Armature Coil Core Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE
1. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.
INSPECT COMMUTATOR CIRCLE RUNOUT
1. Place the commutator on V-blocks.
2. Using a dial indicator, measure the circle runout.
  Maximum circle runout: 0.05 mm (0.0020 in.)
  
  If the circle runout is greater than maximum, correct it on a lathe.
  
  Fig 3: Measuring Circle Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COMMUTATOR DIAMETER
1. Using vernier calipers, measure the commutator diameter.
  Standard diameter: 35.0 mm (1.378 in.)
  
  Minimum diameter: 34.0 mm (1.339 in.)
  
  If the diameter is less than minimum, replace the armature.
  
  Fig 4: Measuring Commutator Diameter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDER CUT DEPTH
1. Check that the undercut depth is clean and free of foreign materials. 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.
  
  Fig 5: Inspecting Undercut Depth
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FIELD COIL FOR OPEN CIRCUIT
1. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.
  If there is no continuity, replace the field frame.
  
  Fig 6: Checking Continuity Between Lead Wire & Field Coil Brush Lead
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SHUNT COIL FOR OPEN CIRCUIT
1. Using an ohmmeter, check that there is continuity between the field coil end and field frame.
  If there is no continuity, repair or replace the field frame.
  
  Fig 7: Checking Continuity Between Field Coil End & Field Frame Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT SHUNT COIL FOR OPEN CIRCUIT
1. Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B).
  Resistance: 1.5 to 1.9 Ω at 20 °C(68 °F)
  
  If the resistance is not as specified, replace the field frame.
  
  Fig 8: Measuring Resistance Between Shunt Coil Terminals (A) & (B) Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRUSH 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 field frame.
  
  Fig 9: Measuring Brush Length
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRUSH SPRING LOAD
1. Using a pull scale, measure the spring load by pulling the spring from the brush until they are separated.
  Standard spring installed load: 21.5 to 27.5 N (2.2 to 2.8 kgf, 4.8 to 6.2 lbf )
  
  Minimum installed load: 12.7 N (1.3 kgf, 2.9 lbf)
  
  If the installed load is less than minimum, replace the brush springs.
  
  Fig 10: Measuring Spring Load By Pulling Spring From Brush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 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.
  
  Fig 11: Checking Continuity Between Positive (+) & Negative (-) Brush Holders
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GEAR TEETH
1. Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage.
  If any damage is found, replace the gear or clutch assembly, and also check the drive plate ring gear for wear or damage.
INSPECT CLUTCH PINION GEAR
1. Rotate the pinion gear clockwise, and check that it turns freely. Check that it locks by rotating the pinion gear counterclockwise.
  If necessary, replace the clutch assembly.
  
  Fig 12: Rotating Pinion Gear Clockwise & Checking That It Turns Freely
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT AND REAR BEARING
1. Turn the bearing by hand as applying inward force. If resistance is felt or the bearing sticks, replace the bearing.
DO PULL-IN COIL OPEN CIRCUIT TEST
1. Using an ohmmeter, check that there is continuity between terminals 50 and C.
  If there is no continuity, replace the magnetic switch.
  
  Fig 13: Checking Continuity Between Terminals 50 & C Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DO HOLDING COIL OPEN CIRCUIT TEST
1. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
  If there is no continuity, replace the magnetic switch.
  
  Fig 14: Checking Continuity Between Terminal 50 & Switch Body Using An Ohmmeter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002