Starting

1 ENGINE Z-FE STARTING STARTING SYSTEM (for 0.8 kW Type)

PARTS LOCATION

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SYSTEM DIAGRAM

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1 ENGINE Z-FE STARTING STARTING SYSTEM (for 1.6 kW Type)

PARTS LOCATION

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SYSTEM DIAGRAM

1 ENGINE Z-FE STARTING STARTER (for 0.8 kW Type)

COMPONENTS

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REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

2. REMOVE FLYWHEEL HOUSING SIDE COVER

• (a) Disengage the claw while pushing it upward and remove the flywheel housing side cover.

3. REMOVE STARTER ASSEMBLY

• (a) Remove the terminal cap.
• (b) Remove the nut and remove terminal 30.
• (c) Disconnect the connector.
• (d) Remove the 2 bolts and remove the starter assembly.

DISASSEMBLY

1. REMOVE MAGNET STARTER SWITCH ASSEMBLY
2. (a) Remove the nut, and disconnect the lead wire from the magnet starter switch assembly terminal.
3. (b) Loosen the 2 nuts holding the magnet starter switch assembly onto the starter housing.

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• (c) Pull the magnet starter switch assembly and while lifting the front part of the magnet starter switch assembly, release the plunger hook from the driver lever, then remove the magnet starter switch assembly.

2. REMOVE STARTER YOKE ASSEMBLY

• (a) Remove the 2 through bolts, and pull out the field frame together with the armature.

3. REMOVE STARTER BRUSH HOLDER ASSEMBLY

• (a) Remove the 2 screws and the commutator end frame, and hold down the lead wire while releasing the commutator end frame.

NOTICE:

• To avoid interference between the brush holder and the dust protector, pull the commutator end frame away at an angle.
• (b) Using a screwdriver, hold the spring back and disconnect the brush holder.
• (c) Disconnect the 4 brushes, and remove the brush holder.

4. REMOVE STARTER ARMATURE ASSEMBLY

5. REMOVE STARTER CLUTCH SUB-ASSEMBLY

• (a) Remove the drive lever and starter clutch with shock absorber from starter housing.

• (b) Using a screwdriver, tap in the stop collar toward the starter clutch.

• (c) Using a screwdriver, pry off the snap ring.

• (d) Remove the stop collar and starter clutch from the planetary shaft.

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INSPECTION

1. INSPECT STARTER ASSEMBLY NOTICE:

Perform each of the following tests within 3 to 5 seconds.

• (a) Perform pull-in test.

• (1) Disconnect the field coil lead wire from terminal C.

• (2) Connect the battery to the starter magnetic switch as shown in the illustration and check that the pinion gear is extended.

• (b) Perform holding test.

• (1) Check that the pinion gear does not return inward after the cable of terminal C is disconnected.

• (c) Inspect the clutch pinion gear return.

• (1) Disconnect the negative (-) lead from the starter body and move the pinion gear toward the armature.

• (d) Perform the operation test without load.

• (1) Connect the field coil lead wire to terminal C. Torque: 9.8 Nm (100 kgfcm, 87 in.*lbf)

• (2) Clamp the starter in a vise.

• (3) Connect the battery and ammeter to the starter as shown in the illustration.

• (4) Check that the ammeter indicates the specified current.

Standard current: 90A or less at 11.5V

2. INSPECT STARTER ARMATURE ASSEMBLY

• (a) Check the commutator for open circuits.
• (1) Using an ohmmeter, check the resistance between the segments of the commutator.

Standard resistance:

Below 1 Ω

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

• (b) Check the commutator for ground.
• (1) Using an ohmmeter, check the resistance between the commutator and the armature core.

Standard resistance:

10 k Ω or higher

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

• (c) Check the commutator surface for dirt and burns. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.
• (d) Check for the commutator cirumference runout.
• (1) Place the commutator on V-blocks.
• (2) Using a dial indicator, measure the cirumference runout.

Maximum runout:

0.05 mm (0.0020 in.)

If the runout is greater than the maximum, replace the starter armature assembly.

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• (e) Using vernier calipers, measure the commutator diameter.

Standard diameter:

28.0 mm (1.1024 in.)

Minimum diameter:

27.0 mm (1.0630 in.)

If the diameter is less than the minimum, replace the starter armature assembly.

• (f) Check that the undercut portion between the segments is free of foreign matter and measure its depth.

Standard undercut depth:

0.6 mm (0.0236 in.)

Minimum undercut depth:

0.2 mm (0.0079 in.)

If the undercut depth is less than the minimum, adjust it with a hacksaw blade.

3. INSPECT STARTER YOKE ASSEMBLY

• (a) Using an ohmmeter, check the resistance between terminal C and the field coil brush lead.

Standard resistance:

Below 1 Ω

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

• (b) Using an ohmmeter, check the resistance between the brush lead and the starter yoke.

Standard resistance:

10 k Ω or higher

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

4. INSPECT BRUSH

• (a) Using vernier calipers, measure the brush length.

Standard length:

14 mm (0.5511 in.)

Minimum length:

9 mm (0.3543 in.)

If the length is less than the minimum, replace the starter brush holder assembly and the starter yoke assembly.

5. INSPECT STARTER BRUSH HOLDER ASSEMBLY

• (a) Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brush holders.

Standard resistance:

10 k Ω or higher

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

6. INSPECT STARTER CLUTCH SUB-ASSEMBLY

• (a) Hold the starter clutch and 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 starter clutch subassembly.

7. INSPECT MAGNET STARTER 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 magnet starter switch assembly.
• (b) Check the pull-in coil for open circuits.
• (1) Using an ohmmeter, check the resistance between