Service manual
STARTER
MOTOR
DESCRIPTION
The starter can be roughly divided into the following sections:
• A motor section which generates a drive power.
• An overrunning clutch section which transmits an arma-
ture torque, preventing motor overrun after starting.
• A switch section (solenoid) which is operated when actu-
ating the overrunning clutch through a lever and which
supplies load current to the motor.
The starter is a new type, small, light-weight and is called a
high-speed internal-reduction starter.
The
pinion shaft is sep-
arate from the motor shaft; the pinion slides only on the pin-
ion shaft. A reduction gear is installed between the motor
shaft and a pinion shaft.
The
pinion sliding part is not
exposed outside the starter so that the pinion may slide
smoothly without becoming fouled with dust and grease. The
motor shaft is supported at both ends on ball bearings. The
lever mechanism, switch and overrunning clutch inner circuit
are identical to conventional ones.
ADJUSTMENT
AND
REPAIR
If
any abnormality is found by the following tests, the starter
should be disassembled and repaired.
Pinion
Gap
Inspection
1.
Connect a battery (12V) between the starter terminal S
and the starter body, and the pinion drive should rotate
out and stop.
A
CAUTION:
Never
apply
battery
voltage
for
over
10
seconds
continuously.
2. Lightly push the pinion back and measure the return
stroke (called pinion gap).
3.
If
the pinion gap is not within the standard range, 0.0197
- 0.0788in (0.5 to 2.Omm), adjust it by increasing
or
decreasing the number
of
shims on the solenoid. The gap
is decreased as the number
of
shims increases.
D.S2.DMM
PINION
GAP
No-Load
Test
1.
Connect the ammeter, voltmeter, and battery to the starter
as illustrated.
2. When the switch is closed, the pinion must protrude and
the starter must run smoothly (at
3000 rpm
or
more).
If
the current
or
starter speed is out
of
specification, disas-
semble the starter and repair it.
A
CAUTION:
Use
thick
wires
as
much
as
possible
and
tighten
every
tenninal
securely.
This
is
a
solenoid
shift-
type
starter
which
makes
a
rotating
sound
louder
than
that
of
a
direct-drive
type
starter.
When
detecting
starter
rotation
at
the
pinion
tip,
be
careful
not
to
come
in
contact
with
the
pinion
gear
when
it
protrudes.
SOLENOID
Perform the following tests.
If
any test result is not
satisfactory, replace the solenoid assembly.
1.
Inspect the solenoid for continuity between terminals (+)
and (-) and between terminals S and the body and M
and
the body. There should
be
no continuity found between
terminals S and M. Continuity will
be
found between ter-
minals S and the body and terminal M and the body.
MULTIMETER
NOTE:
Disconnect
the
wire
from terminal
M.
2.
Connect a battery to the solenoid's terminal S for (+) and
M for (-). Have a switch in the
+ lead and close it. The
pinion drive should extend fully out.
A
CAUTION:
Do
not
apply
battery
current
for
more
than
10
seconds
when
testing
the
solenoid.
Engines
&
Generators
45