SECTION 1F CRANKING SYSTEM GENERAL DESCRIPTION Cranking Circuit Starting Motor TROUBLESHOOTING INSPECTION Starting Motor 4FA21 1F — 122 1F — 122 1F —122 1F— 124 1F — 126 1F —1261F-122 GENERAL DESCRIPTION CRANKING CIRCUIT Cranking circuit is consisted of battery, starting rotor, ignition switch and related electrical wring. Only the starting ‘motor willbe covered in this section Ignition eal Ignition switch Distibutor Man fuze Starting motor Battery FIG. 1F—1 CRANKING CIRCUIT STARTING MOTOR tem | Ss OAEWOO Outpat(kKw) 081F-123 —. Starting motor is consisted of the parts shown in Fig. 1F —2, andhas.a permanent magnet mountedin starting motor yoke(trame ‘The magnetic enitchassembly and pais inthe starting motorare enclosedin the housings sothatthey willbe protected againstpossibledirt and water spiash. In the cicuitshown in Fig. 1F — 1, magneticewitch coils ere magnetized when igntionswitch isin “ON position, and the piionis tobe engaged in the ring gear of fywheel by the movingpinion drve lever, This makes magnetic switch tumedto “ON’ and cranking takes place. After stating engine, pinion one-way Clutch protects armature from excessive speed untiignition ewitch tums to OFF”, and when the switch turns 1o OFF, the return spring causes the pinion to disengage, Solenoid assembly Lever assemely Armature Clutch assembly Housing assembly Frane assemoly Holder assemaly Frame assembly FIG. 1F —2 STARTING MOTOR CONFIGURATION DIAGRAM4F-124 rN TROUBLE SHOOTING Fotowing conditonsare found due to the malfunction in the cranking system. + Staring motor does not worklor retarded starting speed). + Engine does not turn with working start motor. + Abnormel noice comes: * Confirm the probable causes in battery, harness {including starting motor switch), starting motor orn any parts of engine. Check the probable causes with the metor stalled bocause the motor can not be started with the starting metor removed. 1. Maifunction details 2. Connectingconsition of battery terminal( grounding cable connections in the engine side) and staring motor terminals 3, Batery charging 4. Installation of starting motor ; = Probable Cause magnetic switch + Cutting of pull in col ‘+ Poor lubrication of plunger + Battery run down + Poor contact in batiory cable magnetic switch + Low elasticity of brush spring + Burt commutator + Malfunction of armature Operational sound of magnetic switch is heard + Low battery voltage due to deterioration : + Burnt main contact point, or poor contacting action of + Brushes are seating poorly or worn : Condition | Correction Starting motor does | No operating sound of magnetic switch not work + Battery run dovin + Charge battery + Low battery votage due to detetioraion +. Replace battery * Poor contact in battary terminal + Ratighten or replace + Loose grounding cable connection + Ratighten + Fuse loosening or cutting + Tighten or replace + Peor contact upon ignition switch + Replace + Loosened ieads «+ Retighten * Cutting cable between ignition switch and + Repair + Replace magnetic switch + Replace Charge battery Replace battery Retighten Replace magnetic swtch Repair or roplace + Replace + Replace + Replace1F-125, —————————————— ee AIS Condition Probable Cause Correction Staring moter Inspect starting motor when no defect is found ‘unning, but too | on battery or wiring sides. slow + Poor contact of main joints of magnet switch + Replace {insufficient torque) | + Malfunction of armature + Replace + Disconnected, burnt or worn commutator + Repair or replace + Abrasion or bum of brush + Replace + Replace Starting motor running, but not cranking engine Noise Starting motor won'tstop + Low elasticity of brush spring + Worn pinion chip, + Poor lubrication of one-way clutch + Clutch idling due to defect of raller spring + Worn ring gear + Abnormal abrasion of brush + Wor pinion ring gear + Poor lubrication of pinion + Worn inner teeth of idle gear + Fused contacts of magnetic switch + Matfunction of magnetic switch + Fallure retuming action in ignition switen + Replace one- way elutch + Replace one-way clutch + Replace one-way clutch + Roplace fywheo! + Replace + Replace pinion, flywheel + Replace ‘+ Repair ar replace + Replace + Replace otINSPECTION STARTING MOTOR Replace armature ifthe outerdiameterof worn commu: talor is below the folowing standard. 1. Armature Inspection : mes: Ouier diameter of Standard | Lit Inspect commutator for ditt or bum. Remove with ymmutator sandpaper or iatne, It necessary commutatorinm) | 31.90 32.60 FG. F—3 Chack commutator for unevan wear. If deflection of dial BG pS Check commutator for mica thickness, Repait or re- ip porter axcoads iit epaF op ee eee ania esas pie blo the rt Commutator Mica | Standard | Limit thiekness(mm) SET aE CAUTION If the bent exceads below speci ation, 1 7 replace the armature. above |_| Standard | Limit =e Mica Comnmmutateroutotreund¢nm) |= = \ 0.05 seamen | | 05-08 Sh | fT Conect incorect Fig. 1F 6 FIG.1F—4 ]Ground Test Check commutator and armature. Ifthere is continuity, armature is grounded and must be replaced FIG. 1F 7 Open Circuit Test Check for continuity between segments. Hf there is no Continuity at ary test point, there is an open circuit and amature must be replaced FIG. 1F 8 2. Brush Inspection the length of wom brush is below the following value, replace the brush | | Standard Umit Brush Length mm) 700-725 | FIG. 1F91F-128 3. Performance Test CAUTION Finish testin 3-5 seconds nottomake coil burnt. Check plunger return Disconnect © lead from switch body and check punger retuming inward. If plunger does not retum, replace magnetic switch, Pullin test Connect battery to magnetic switch as shown below, land check that plunger moves outward. If the plunger does not move, replace magnetic switch. SBAT FIG. 1F—10 Hold-in test While connected as above with plungercut, disconnect ‘lead from terminal M, and check the plungerreturning inward. If the plunger retums inward, replace the magnetic switch FIG.1F—11 FIG. 1F—12 No- load performance test a) Connect the battery and ammeter to starting motor as shown below, b) Check that starting motor rotates smoothy and steadily with pinion moving out, Check that amme- ‘er reads the specified current. “peaked ewnia) [less hanan aT18] FIG.1F -13