STARTING SYSTEM (for 0.8 kw Type) > PARTS LOCATION

Transcription

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58 Communication table: Sender Receiver Signal Line ECM Main body ECU Engine rotation signal CAN Meter ECU Main body ECU Vehicle speed signal CAN Steering lock ECU Main body ECU Steering lock/unlock signal LIN Certification ECU Main body ECU LIN master signal LIN Main body ECU ID code box ID required signal LIN Main body ECU Certification ECU Key existence condition signal LIN ENTRY AND START SYSTEM >

59 SYSTEM DESCRIPTION ENTRY AND START DESCRIPTION 1. The entry and start uses a push-type ignition switch, which the driver can operate by merely carrying the key. This system consists primarily of the main body ECU, ignition switch, ID code box, steering lock ECU, key, ACC CUT relay, IG1 relay, IG2 relay and certification ECU. The main body ECU controls the system. This function operates in cooperation with the entry and start system. The table below shows the transition of the ignition switch, which depends on whether the clutch pedal is depressed or released. 2. This system has different power source mode patterns depending on the clutch pedal conditions. Clutch Pedal Not depressed For M/T: Power Source Mode Pattern Each time ignition switch is pushed off on (ACC) on (IG) off When ignition switch is pushed in the engine started condition Not depressed Engine started off When ignition switch is pushed once Depressed off engine start When ignition switch is pushed in the on (ACC) condition Depressed on (ACC) engine start Depressed When ignition switch is pushed in the on (IG) condition

60 on (IG) engine start When ignition switch is pushed in the engine started condition Depressed Engine started off Brake Pedal Shift Lever Depressed N Position For except M/T: Power Source Mode Pattern 7. When the engine switch is pushed once. OFF IG ON (after the engine is started) Not Depressed N Position Except N Position 8. Each time the engine switch is pushed. OFF ACC IG ON OFF 9. Each time the engine switch is pushed. OFF ACC IG ON OFF - N Position 10. When the engine switch is pushed in the IG- ON condition. IG ON (engine is started or not started) OFF - Except N Position 11. When the engine switch is pushed in the IG- ON condition. IG ON (engine is started or not started) OFF When the battery of the key is low, the entry and start function can be operated by holding the key against the ignition switch. FUNCTION OF COMPONENT

61 Components Ignition Switch (Transponder Key Amplifier) Key Indoor Electrical Key Oscillator (Front and Rear) Entry Door Control Receiver Main Body ECU Function Transmits ignition switch signal to main body ECU. Informs driver of power source mode or system abnormality with indicator light illumination. Receives ID code and transmits it to certification ECU when battery of key is low. Receives signals from oscillators and returns ID code to entry door control receiver. Receives request signal from certification ECU and forms detection area in vehicle interior. Receives ID code from key and transmits it to certification ECU. Changes power source mode in 4 stages (off, on (ACC), on (IG), start) in accordance with state of clutch start switch or park/neutral start switch. Controls entry and start function in accordance with signals received from switches and each ECU. Certification ECU Stop Light Switch Clutch Start Switch (M/T) ID Code Box ECM Certifies ID code received from entry door control receiver and transmits certification results to ID code box and steering lock ECU. Outputs state of brake pedal to main body ECU. Outputs state of clutch pedal to main body ECU. Receives steering unlock or engine immobiliser unset signals from certification ECU, certifies them, and transmits each unset signal to steering lock ECU or ECM. Receives engine start request signal from power source control ECU, turns ON ST relay, and starts engine. Receives signal from immobiliser code ECU and performs engine ignition and injection.

62 SYSTEM FUNCTION The electric controls of the entry and start function are described below: Control Ignition Switch Control Diagnosis Outline When driver operates ignition switch with key in driver's possession, certification ECU starts indoor electrical key oscillator, which transmits request signal to key. Upon receiving this signal, key transmits ID code signal to main body ECU. ID code box verifies check results received from certification ECU via LIN and sends them to main body ECU. Based on these results, main body ECU authorizes operation of ignition switch. When main body ECU detects malfunction, main body ECU diagnoses and memorizes failed section. CONSTRUCTION AND OPERATION 1. Ignition Switch Ignition switch consists of a momentary type switch, 3 color (amber, green, greenish white) LEDs, and transponder key amplifier. The greenish white LED is for illumination. The amber and green LEDs are for the indicator lights. The driver can check the present power source mode and whether the engine can start or not in accordance with the illumination state of the indicator light. When the main body ECU detects an abnormality in the entry and start system, it makes the amber indicator light flash. If the engine stopped in this state, it might not be possible to restart it. 2. Indicator Light Condition

63 Power Source Mode/Condition Ignition switch indicator light condition Clutch pedal released (M/T) Brake pedal released (except M/T) Indicator Light Condition Clutch pedal depressed (M/T) Brake pedal depressed (except M/T) Off OFF Illuminates (Green) On (ACC, IG) Illuminates (Amber) Illuminates (Green) Engine running OFF OFF Steering lock not unlocked System malfunction Clutch switch malfunction (M/T) Flashes (Green) for 15 seconds Flashes (Amber) for 15 seconds Flashes (Green) for 15 seconds Flashes (Green) for 15 seconds Flashes (Amber) for 15 seconds Flashes (Green) for 15 seconds 3. Main Body ECU The main body ECU consists of the IG1 and IG2 relay actuation circuits and CPU. WHEN KEY BATTERY IS LOW

64 1. To operate the entry and start function when the key battery is low, hold the TOYOTA mark of the key against the ignition switch while depressing the brake pedal. 2. The main body ECU transmits a key verification request signal from the stop light switch to the certification ECU. 3. The certification ECU does not receive an ID code response from the smart tuner, so it actuates the transponder key amplifier built into the ignition switch. 4. The transponder key amplifier outputs an engine immobiliser radio wave to the key. 5. The key receives the radio wave, and returns a radio wave response to the transponder key amplifier. 6. The transponder key amplifier combines the key ID codes with the radio wave response, and transmits it to the certification ECU. 7. The certification ECU judges and verifies the ID code, and transmits a key verification OK signal to the main body ECU. The buzzer in the combination meter sounds at the same time. 8. After the buzzer sounds, if the ignition switch is pressed within 5 seconds with the brake pedal not depressed, the power source mode changes to on (ACC) or on (IG), the same as in the normal condition.

65 DIAGNOSIS The main body ECU can detect malfunctions in the entry and start function when the power source mode is on (IG). When the ECU detects a malfunction, the amber indicator light of the ignition switch flashes to warn the driver. At the same time, the ECU stores the 5-digit DTC (Diagnostic Trouble Code) in the memory. The indicator light warning continues for 15 seconds even after the power source mode is changed to off. The DTC can be read by connecting the intelligent tester to the DLC3. The entry and start function cannot be operated if a malfunction occurs.

66 ENTRY AND START SYSTEM > HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use these procedures to troubleshoot the push-button start function. *: Use the intelligent tester. 1.VEHICLE BROUGHT TO WORKSHOP NEXT 2.INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3.INSPECT COMMUNICATION FUNCTION OF LIN COMMUNICATION SYSTEM* 1. Using the intelligent tester, check if the LIN Communication System is functioning normally (). Result

67 B. GO B. GO C. GO Result DTC is not output DTC is output Proceed to A B TO DIAGNOSTIC TROUBLE CODE C A 4.CHECK FOR DTC* 1. Check for DTCs and note down any stored DTCs ( ). 2. Delete the DTC. 3. (c) Check whether the same DTC(s), relevant to the SFI or entry and start systems, recurs by reproducing the symptoms indicated by the noted DTC(s) in step (a) above. Result Result DTC output does not reoccur SFI system (1KR-FE) DTC output reoccurs Entry and start system DTC output reoccurs Proceed to A B C TO SFI SYSTEM (1KR-FE) TO STEP 7 A 5.PROBLEM SYMPTOMS TABLE

68 B. GO Result Result Fault is not listed in problem symptoms table Fault is listed in problem symptoms table Proceed to A B TO STEP 7 A 6.OVERALL ANALYSIS AND TROUBLESHOOTING* 1. Terminals of ECU () 2. Data List/Active Test () NEXT 7.ADJUST, REPAIR OR REPLACE NEXT 8.CONFIRMATION TEST NEXT END

69 ENTRY AND START SYSTEM > PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the causes of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected area in the order they are listed. Replace parts as necessary.

70 Symptom Power Source Mode does not Change Engine does not Start Engine Switch Indicator Circuit Entry and Start System Suspected area Ignition Switch Indicator Circuit Room Oscillator does not Recognize Key Ignition Switch Electrical Key ID Code Box Main Body ECU Wire Harness Push-button Start Function DTCs Power Source Mode does not Change Steering Lock System SFI System (1KR-FE) Ignition Switch Stop light switch Park/Neutral position switch Main Body ECU Wire Harness Ignition Switch Main Body ECU Wire Harness See page

71 ENTRY AND START SYSTEM > PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the causes of the problem symptom. The potential cases of the symptoms are listed in order of probability in the "Suspected Area" column of the table. Check each symptom by checking the suspected area in the order they are listed. Replace parts as necessary. Symptom Power Source Mode does not Change Entry and Start System Suspected area Ignition Switch Indicator Circuit Room Oscillator does not Recognize Key Ignition Switch Electrical Key (TMC made) Electrical Key (TMMF made) ID Code Box Main Body ECU Wire Harness See page

72 Engine does not Start Engine Switch Indicator Circuit Entry and Start Function DTCs Power Source Mode does not Change Steering Lock System SFI System (1KR-FE) Ignition Switch Stop light switch Park/Neutral position switch Main Body ECU Wire Harness Ignition Switch Main Body ECU Wire Harness

73 ENTRY AND START SYSTEM > TERMINALS OF ECU CHECK POWER SOURCE CONTROL ECU

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75 1. Disconnect the 4B, 4D, 4E and D65 ECU connectors. 2. Measure the voltages and resistances of the wire harness side connectors. Standard

76 Symbols (Terminal No.) BECU (4B-30) - Body ground AM1 (D65-1) - Body ground AM2 (D64-6) - Body ground SSW1 (D65-10) - Body ground SSW1 (D65-10) - Body ground SSW2 (D65-9) - Body ground SSW2 (D65-9) - Body ground GND1 (4E-17) - Body ground GND2 (D65-4) - Body ground LIN1 (4D-9) - Body ground Wiring Color L - Body ground O - Body ground SB - Body ground R - Body ground R - Body ground L - Body ground L - Body ground W-B - Body ground W-B - Body ground P - Body ground Terminal Description +B power supply +B power supply +B power supply Ignition switch signal Ignition switch signal Ignition switch signal Ignition switch signal Condition Always Always Always Ignition switch pushed Ignition switch not pushed Ignition switch pushed Ignition switch not pushed Specified Condition 10 to 14 V 10 to 14 V 10 to 14 V Below 1 Ω 10 kω or higher Below 1 Ω 10 kω or higher Ground Always Below 1 Ω Ground Always Below 1 Ω LIN line Always 10 kω or higher 3. If the result is not as specified, there may be a malfunction on the wire harness side. 4. Reconnect the 4B, 4D, 4E and D65 ECU connectors. 5. Measure the voltages of the connectors. Symbols (Terminal No.) ACCD (D64-4) - GND2 (D65-4) ACCD (D64-4) - GND2 (D65-4) Wiring Color LG - W-B LG - W-B Standard voltage Terminal Description ACC signal Condition Specified Condition Ignition switch on (ACC) 10 to 14 V ACC signal Ignition switch off Below 1 V IG2D (D65-5) P - W- IG2 signal Ignition switch on (IG) 10 to 14 V

77 - GND2 (D65-4) B IG2D (D65-5) - GND2 (D65-4) P - W- B IG2 signal Ignition switch on (ACC) Below 1 V SLR+ (D64-7) - GND2 (D65-4) L - W- B Steering lock motor signal Steering lock motor operating Below 1 V SLR+ (D64-7) - GND2 (D65-4) L - W- B Steering lock motor signal Steering lock motor does not operate 10 to 14 V SLP (D64-18) - GND2 (D65-4) GR - W-B Steering lock actuator position signal Steering lock locked 10 to 14 V SLP (D64-18) - GND2 (D65-4) GR - W-B Steering lock actuator position signal Steering lock released Below 1 V SPD (4C-8) - GND2 (D65-4) SB - W-B Speed signal from combination meter Ignition switch on (IG), Rotate driving wheel slowly Pulse generation (see waveform 1) TACH (D66-2) - GND2 (D65-4) L - W- B Tachometer signal Engine running Pulse generation (see waveform 2) STSW (D66-4) - GND2 (D65-4) B - W- B Starter activation request signal Clutch pedal (M/T) or brake pedal (except M/T) depressed, ignition switch pushed once 10 to 14 V* STR (D66-3) - GND2 (D65-4) GR - W-B Clutch pedal switch Clutch pedal (M/T) or brake pedal (except M/T) depressed Below 1 V STR2 (D66-14) - GND2 (D65-4) O - W- B Starter signal Clutch pedal (M/T) or brake pedal (except M/T) depressed, ignition switch pushed once 10 to 14 V* INDS (D66-1) - GND2 (D65-4) SB - W-B Vehicle condition signal Clutch pedal (M/T) or brake pedal (except M/T) depressed, ignition switch off, on (ACC, IG) 10 to 14 V

78 INDW (D66-8) - GND2 (D65-4) STP (D64-14) - GND2 (D65-4) SWIL (D65-8) - GND2 (D65-4) Y - W- B G - W- B LG - W-B Vehicle condition signal Clutch pedal (M/T) or brake pedal (except M/T) released, ignition switch off, on (ACC, IG) 10 to 14 V Stop light switch Brake pedal depressed Below 1 V Illumination signal Light control switch TAIL or HEAD 6. HINT: 7. *: Voltage is output for 0.3 seconds after the engine is started. 8. If the result is not as specified, the ECU may have a malfunction to 14 V 10. Inspect the connectors using an oscilloscope. 1. Waveform 1 Item Symbols (Terminal No.) Tool Setting Condition Content SPD (4C-8) - GND2 (D65-4) 5 V/DIV., 10 msec./div. Driving at approx. 20 km/h (12 mph)

79 2. HINT: 3. As the vehicle speed increases, the wavelength shortens Waveform 2 Item Symbols (Terminal No.) Content TACH (D66-2) - GND2 (D65-4) Tool Setting 5 V/DIV., 10 msec./div. Condition Engine idling 6. HINT: 7. As the vehicle speed increases, the wavelength shortens. CHECK CERTIFICATION ECU

80 1. Disconnect the D60 ECU connector. 2. Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) +B1 (D60-1) - Body ground IG (D60-18) - Body ground IG (D60-18) - Body ground LIN (D60-10) - Body ground E (D60-17) - Body ground Wiring Color B - Body ground BR - Body ground BR - Body ground P - Body ground W-B - Body ground Standard Terminal Description +B power supply Ignition power supply Ignition power supply LIN line Condition Always Ignition switch on (IG) Ignition switch off Always Specified Condition 10 to 14 V 10 to 14 V Below 1 V 10 kω or higher Ground Always Below 1 Ω 3. If the result is not as specified, there may be a malfunction on the wire harness side. CHECK ECM

81 1. Disconnect the A32 and C33 ECM connectors. 2. Measure the voltages and resistances of the wire harness side connectors. Symbols (Terminal No.) BATT (A32-22) - E1 (A32-1) +B (A32-24) - E1 (A32-1) +B1 (A32-23) - E1 (A32-1) IGSW (A32-4) - E1 (A32-1) E1 (A32-1) - Body ground E2 (C33-36) - Body ground E21 (C33-35) - Body ground E01 (A32-20) - Body ground Wiring Color V - W-B B - W-B B - W-B R - W-B W-B - Body ground P - Body ground G - Body ground W-B - Body ground Standard Terminal Description Battery (for measuring battery voltage and for ECM memory) Power source of ECM Power source of ECM Ignition switch signal Condition Always Ignition switch on (IG) Ignition switch on (IG) Ignition switch on (IG) Specified Condition 10 to 14 V 10 to 14 V 10 to 14 V 10 to 14 V Ground Always Below 1 Ω Ground Always Below 1 Ω Ground Always Below 1 Ω Ground Always Below 1 Ω 3. If the result is not as specified, there may be a malfunction on the wire harness side. 4. Reconnect the A32 and C33 ECM connectors. 5. Measure the voltage of the connectors. Symbols (Terminal No.) Wiring Color Standard voltage Terminal Description Condition Specified Condition STA (A32-27) - BR - W- Starter relay Cranking 5.5 V or more

82 E1 (A32-1) B operation signal ACCR (C33-4) - E1 (A32-1) TACH (A32-32) - E1 (A32-1) STAR (C33-80) - E1 (A32-1) G - W-B LG - W- B O - W-B ACC relay cut signal (output) Engine revolution signal (output) Starter relay drive signal Ignition switch on (IG) Cranking Idling Cranking 10 to 14 V Below 1 V Pulse generation (see waveform 1) 10 to 14 V 6. If the result is not as specified, the ECM may have a malfunction Inspect the connector using an oscilloscope. 1. Waveform 1 Item Symbols (Terminal No.) Content TACH (A32-32) - E1 (A32-1) Tool Setting 5 V/DIV., 10 msec./div. Condition Engine idling 2. HINT: 3. As the vehicle speed increases, the wavelength shortens.

83 CHECK STEERING LOCK ECU 1. Disconnect the D56 ECU connector. 2. Measure the voltage and resistance of the wire harness side connector. Symbols (Terminal No.) B (D56-7) - Body ground IG2 (D56-6) - Body ground IG2 (D56-6) - Body ground GND (D56-1) - Body ground SGND (D56-2) - Body ground Wiring Color R - Body ground R - Body ground R - Body ground W-B - Body ground W-B - Body ground Standard Terminal Description +B power supply Ignition power supply Ignition power supply Condition Always Ignition switch on (IG) Ignition switch off Specified Condition 10 to 14 V 10 to 14 V Below 1 V Ground Always Below 1 Ω Ground Always Below 1 Ω 1. If the result is not as specified, there may be a malfunction on the wire harness side. 3. Reconnect the D56 ECU connector. 4. Measure the voltage of the connector. Standard voltage

84 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition SLP1 (D56-4) - GND (D56-1) GR - W- B Steering lock actuator position signal Steering lock locked 10 to 14 V SLP1 (D56-4) - GND (D56-1) GR - W- B Steering lock actuator position signal Steering lock released Below 1 V 1. If the result is not as specified, the ECU may have a malfunction. ENTRY AND START SYSTEM > DIAGNOSIS SYSTEM

85 CHECK DLC3 1. The ECU uses ISO for communication. The terminal arrangement of the DLC3 complies with ISO and matches the ISO format. Symbols (Terminal No.) SIL (7) - SG (5) CG (4) - Body ground SG (5) - Body ground BAT (16) - Body ground CANH (6) - CANL (14) CANH (6) - CG (4) CANL (14) - CG (4) CANH (6) - BAT (16) Terminal Description Bus " +" line Condition During transmission Specified Condition Pulse generation Chassis ground Always Below 1 Ω Signal ground Always Below 1 Ω Battery positive Always 10 to 14 V CAN bus line HIGH-level CAN bus line LOW-level CAN bus line HIGH-level CAN bus line Ignition switch off* Ignition switch off* Ignition switch off* Ignition switch off* 54 to 69 Ω 200 Ω or higher 200 Ω or higher 6 kω or higher

86 CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch off* 6 kω or higher 2. NOTICE: 3. *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. 4. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester to the DLC3, turn the ignition switch on (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in the tester's instruction manual. INSPECT BATTERY VOLTAGE If the voltage is below 11 V, recharge or replace the battery before proceeding. Standard voltage: 11 to 14 V

87 ENTRY AND START SYSTEM > DTC CHECK / CLEAR CHECK DTC

88 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the intelligent tester ON. 3. Select the following menu items: Body / Body ECU / DTC. 4. Check DTCs and then write them down. HINT: For further information about using the intelligent tester, refer to the instruction manual. 5. Confirm the details of the DTCs. CLEAR DTC (using the intelligent tester) 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) (do not start the engine) and turn the intelligent tester ON. 3. Select the following menu items: Body / Body ECU / DTC / Clear. HINT: Refer to the intelligent tester operator's manual for further details. 4. Erase DTCs by pressing the YES button on the tester. HINT: For further information about using the intelligent tester, refer to the instruction manual. CLEAR DTC (not using the intelligent tester)

89 1. Remove the ECU-B fuse from the engine room R/B for more than 60 seconds, or disconnect the negative battery cable for more than 60 seconds. ENTRY AND START SYSTEM > DATA LIST / ACTIVE TEST DATA LIST

90 HINT: Using the intelligent tester's Data List allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the Data List in troubleshooting is one way to save time. NOTICE: In the table below, the values listed under Normal Conditions are for reference only. Do not depend solely on these values when determining whether or not a part is faulty. 1. Turn the ignition switch off. 2. Connect the intelligent tester to the DLC3. 3. Turn the ignition switch on (IG) and turn the tester ON. 4. Select the following menu items: Body / Body ECU / Data List. 5. Check the values by referring to the table below. Item IG SW ACC SW St SW1 St SW2 Str Unlock SW N SW / C SW Stop Lamp Measurement Item / Display (Range) Ignition switch / ON or OFF Ignition switch / ON or OFF Start switch 1 / ON or OFF Start switch 2 / ON or OFF Steering lock condition / ON or OFF Clutch switch (M/T) or park/neutral position switch (except M/T)/ ON or OFF Main body ECU Stop light switch/ ON or OFF Normal Condition ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (ACC) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Steering is unlocked OFF: Steering is locked ON: Clutch pedal is depressed (M/T) or Shift position is N (except M/T) OFF: Clutch pedal is released or Shift position is except N (except M/T) ON: Brake pedal is depressed Diagnostic Note

91 SW1 Vehicle Spd Sig E/G Cond IG1 Relay Mon1 IG2 Relay Mon1 IG1 Relay Mon2 IG2 Relay Mon2 ACC Relay Mon Ratch Circuit Start Req Sig Pwr Cond #Code Vehicle speed signal / STOP or RUN Engine condition / STOP or RUN IG1 outer relay monitor / ON or OFF IG2 outer relay monitor / ON or OFF IG1 inner relay monitor / ON or OFF IG2 inner relay monitor / ON or OFF ACC relay monitor / ON or OFF Ratch circuit / ON or OFF Starter request signal / ON or OFF Power supply condition / ALL, ACC ON, IG1 IG2, ST ON Number of diagnosis codes / Min: 0, max: 255 OFF: Brake ped STOP: Vehicle is stopped RUN: Vehicle is running STOP: Engine is stopped RUN: Engine is running ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off ON: Ignition switch is on (ACC) OFF: Ignition switch is off ON: Ignition switch is on (IG) OFF: Ignition switch is off, on (ACC) or engine is running ON: ST relay is ON OFF: ST relay is OFF ALL: All relays are ON ACC ON: ACC relay is ON IG1: IG1 relay is ON IG2: IG2 relay is ON ST ON: ST relay is ON Item Certification ECU Measurement Item / Range (Display) Normal Condition Diagnostic Note

92 IG SW Ignition switch / ON or OFF ON: Ignition switch is on (IG) OFF: Ignition switch is off - ACC SW Ignition switch / ON or OFF ON: Ignition switch is on (ACC) OFF: Ignition switch is off - Key Lobatt Wrn Electrical key battery conditions / ON or OFF ON: Battery has been depleted OFF: Battery is not depleted - Unmatch Format Code format/ YES or NO YES: Code format matches NO: Code format differs - No response Response/ YES or NO YES: Response NO: No response - Wrong Code ID code/ YES or NO YES: ID code matches NO: ID code differs - Wrong C Code Challenge code/ YES or NO YES: Challenge code matches NO: Challenge code differs - Unmatch V-ID Key number/ YES or NO YES: Key number matches NO: Key number differs - Permit (Start) Engine start permission by certification ECU/ PERMIT or PROHIBIT PERMIT: Engine start is permitted PROHIBIT: Engine start is prohibited - Start Rqst Starter request signal / ON or OFF YES: Engine switch off NO: ST relay is OFF - S Code Chk S code certification result/ NG or OK NG: S code certification result is abnormal OK: S code certification result is normal -

93 L Code Chk L code certification result/ NG or OK NG: L code certification result is abnormal OK: L code certification result is normal - ACTIVE TEST HINT: Performing an Active Test enables components including the relays, VSV (Vacuum Switching Valve), and actuators, to be operated without removing any parts. The Active Test can be performed with an intelligent tester. Performing an Active Test as the first step of troubleshooting is one method of shortening diagnostic time. Data List can be displayed during Active Tests. 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch to on (IG). 3. Turn the tester ON. 4. Select the following menu items: Body / Body ECU / Active Test. 5. Perform the Active Test by referring to the table below. Main body ECU Item Test Details Diagnostic Note Lighting Ind Ind Condition S Lock Pwr Indicator illumination ON/OFF Indicator light illumination pattern Green/Amber/No Sig Steering lock ECU power supply ON/OFF Certification ECU Item Test Details Diagnostic Note Fr Transmitter Indoor electrical key antenna (front) ON / OFF -

94 ENTRY AND START SYSTEM > DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, inspect the suspected areas listed for that code. For details of the code, refer to the "See page" in the DTC chart. Inspect the fuse and relay before investigating the suspected areas shown in the table below.

95 DTC No. Detection Item Entry and Start System B2271 Ignition Hold Monitor Malfunction B2272 Ignition 1 Monitor Malfunction B2273 Ignition 2 Monitor Malfunction B2274 ACC Monitor Malfunction B2275 STSW Monitor Malfunction B2276 ACCR Signal Circuit Malfunction B2277 Detecting Vehicle Submersion B2278 Engine Switch Circuit Malfunction B2282 Vehicle Speed Signal Malfunction B2283 Vehicle Speed Sensor Malfunction B2285 Steering Lock Position Signal Circuit Malfunction B2286 Runnable Signal Malfunction B2287 LIN Communication Master Malfunction Trouble Area - Main body ECU - AM2 fuse - Wire harness - Main body ECU - IG1 relay - Wire harness - Main body ECU - IG2 relay - Wire harness - Main body ECU - ACC cut relay - Wire harness - Main body ECU - SFI system - Wire harness - Main body ECU - SFI system - Wire harness Main body ECU - Main body ECU - Ignition switch - Wire harness - Main body ECU - Combination meter - Wire harness - Main body ECU - Combination meter - Speed sensor - Skid control ECU - Wire harness - Main body ECU - Steering lock system - Wire harness - Main body ECU - SFI system - Wire harness - Main body ECU - Certification ECU - Wire harness See page

96 B2288 Steering Lock Signal Circuit Malfunction B2289 Key Collation Waiting Time Over - Main body ECU - Steering lock system - Wire harness - Main body ECU - Entry function - Engine immobiliser system - Ignition switch - Electrical key - Wire harness

97 ENTRY AND START SYSTEM > Power Source Mode does not Change DESCRIPTION When the certification ECU has detected the electrical key inside the cabin, the power source mode can be changed in the following order sequentially by pressing the ignition switch: Off On (ACC) On (IG) Off. When either one of the DTCs shown in the illustration below is detected, troubleshoot the DTC(s) by following the troubleshooting procedure relevant to the DTC(s). If the power source mode is still not changed normally, despite troubleshooting, one of the following may have occurred: The LIN communication line is malfunctioning. The certification ECU has determined that no key is inside the cabin. The ignition switch is malfunctioning. The main body ECU is malfunctioning.

98 INSPECTION PROCEDURE 1.CHECK WHETHER DTC OUTPUT RECURS 1. Clear the DTCs. HINT: After all DTCs are cleared, check if the trouble occurs again 5 seconds after the ignition switch is turned on (IG). 2. Check for DTCs again. OK: No DTC is output.

99 NG GO TO DTC CHART OK 2.CHECK BASIC FUNCTION 1. Carry the key into the vehicle. 2. Depress the clutch pedal (M/T) or brake pedal (except M/T) and check that the ignition switch indicator illuminates in green. OK: Ignition switch indicator illuminates in green.

100 NG Go to step 10 OK 3.INSPECT FUSE (AM2)

101 1. Remove the AM2 fuse from the engine room R/B and J/B. 2. Check the fuse resistance. Standard resistance: Below 1 Ω 3. Reinstall the AM2 fuse.

102 NG REPLACE FUSE OK 4.READ VALUE OF INTELLIGENT TESTER (RELAY MONITOR) 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester ON. 3. Select the following menu items: Body/ Main Body ECU/ Data List / IG1 Relay Mon2, IG2 Relay Mon2 and ACC Relay Monitor.

103 4. Read the display on the tester. Main Body ECU: Item IG1 Relay Mon2 IG2 Relay Mon2 ACC Relay Monitor OK: ON appears on the screen. Measurement Item / Display (Range) IG1 inner relay monitor / ON or OFF IG2 inner relay monitor / ON or OFF ACC relay monitor / ON or OFF Normal Condition ON: Ignition switch on (IG) OFF: Ignition switch off ON: Ignition switch on (IG) OFF: Ignition switch off ON: Ignition switch on (ACC) OFF: Ignition switch off

104 OK REPLACE MAIN BODY ECU NG 5.INSPECT RELAYS (IG1RELAY, IG2 RELAY AND ACC CUT RELAY)

105 1. Inspect the IG1 relay. 1. Remove the IG1 relay from the main body ECU. 2. Check the resistance. Standard resistance: Tester Specified Condition Connection kω or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 3. Reinstall the IG1 relay. 2. Inspect the integration relay (IG2 relay). 1. Remove the integration relay from the engine R/B and J/B.

106 2. Measure the resistance. Standard resistance: Tester Specified Condition Connection 1B-4-1C-1 10 kω or higher 1B-4-1C-1 Below 1 Ω (When battery voltage applied to terminals 1B-2 and 1B-3) 3. Reinstall the integration relay. 3. Inspect the ACC cut relay. 1. Remove the ACC cut relay. 2. Check the resistance. Standard resistance: Tester Specified Condition Connection kω or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 3. Reinstall the relay.

107 NG REPLACE RELAY OK 6.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - INTEGRATION RELAY (IG2 RELAY))

108 1. Remove the integration relay from the engine R/B and J/B. 2. Disconnect the D65 main body ECU connector. 3. Measure the resistance of the wire harness side connectors. Standard resistance:

109 Tester Connection 1B-2 (Integration relay) - D65-5 (IG2D) 1B-3 (Integration relay) - Body ground 1B-2 (Integration relay) or D65-5 (IG2D) - Body ground Specified Condition Below 1 Ω Below 1 Ω 10 kω or higher 4. Reinstall the integration relay. 5. Reconnect the ECU connector.

110 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 7.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - ACC CUT RELAY)

111 1. Remove the ACC cut relay. 2. Disconnect the D64 main body ECU connector. 3. Measure the resistance of the wire harness side connectors. Standard resistance: Tester Connection ACC cut relay (D73-2) - ACCD (D64-4) Specified Condition Below 1 Ω 4. Reinstall the ACC cut relay.

112 5. Reconnect the main body ECU connector. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK 8.INSPECT IGNITION SWITCH ASSEMBLY

113 1. Remove the ignition switch. 2. Measure the resistance of the switch. Standard resistance: Tester Connection 7 (SS1) - 5 (GND) 2 (SS2) - 5 (GND) 7 (SS1) - 5 (GND) 2 (SS2) - 5 (GND) Switch Condition Pushed Pushed Not pushed Not pushed Specified Condition Below 1 Ω Below 1 Ω 10 kω or higher 10 kω or higher 3. Reinstall the ignition switch.

114 NG REPLACE IGNITION SWITCH ASSEMBLY OK 9.CHECK HARNESS AND CONNECTOR (MAIN BODY ECU - BATTERY AND BODY GROUND)

115 1. Disconnect the D64 and D65 main body ECU connectors. 2. Measure the voltage and resistance of the wire harness side connector. Standard voltage: Tester Connection D65-1 (AM1) - Body ground D64-6 (AM2) - Body ground Standard resistance: Specified Condition 10 to 14 V 10 to 14 V

116 Tester Connection D65-4 (GND2) - Body ground Specified Condition Below 1 Ω 3. Reconnect the main body ECU connectors. NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK

117 REPLACE MAIN BODY ECU 10.CHECK WIRELESS DOOR LOCK AND UNLOCK OPERATION 1. Check that the wireless door lock and unlock functions operate normally. OK: Wireless door lock functions operate normally. NG GO TO WIRELESS DOOR LOCK CONTROL SYSTEM OK

118 11.CHECK OPERATION OF ELECTRICAL KEY 1. After replacing the electrical key with a normally functioning one, check that the wireless lock and unlock functions operate normally. OK: Wireless lock and unlock functions operate normally. OK END (ELECTRICAL KEY IS DEFECTIVE) NG

119 12.PERFORM ACTIVE TEST BY INTELLIGENT TESTER (INDOOR ELECTRICAL KEY OSCILLATOR) 1. Select the Active Test, use the intelligent tester to generate a control command, and then check that the oscillator operates. Certification ECU: Item Test Details Diagnostic Note Indoor electrical key oscillator (front) Fr Transmitter ON / OFF OK: Oscillator function operate normally. -

120 OK GO TO ROOM OSCILLATOR DOES NOT RECOGNIZE KEY (DOOR LOCK SECTION) NG 13.CHECK INDOOR ELECTRICAL KEY OSCILLATOR 1. Carry the key into the vehicle. 2. Replace the indoor electrical key oscillator with a new one. 3. Depress the clutch pedal (M/T) or brake pedal (except M/T) and check that the ignition switch indicator illuminates in green.

121 OK: Ignition switch indicator illuminates in green. NG REPLACE CERTIFICATION ECU OK END (INDOOR ELECTRICAL KEY OSCILLATOR IS DEFECTIVE)

122 ENTRY AND START SYSTEM > Engine does not Start DESCRIPTION ENGINE START SYSTEM OPERATION 1. Except M/T: If the engine switch is pressed with the shift lever in P (A/T) or N and the brake pedal depressed, the main body ECU determines that it is an engine start request.

123 2. M/T: When the ignition switch is pressed with the clutch pedal depressed, the main body ECU determines that it is an engine start request. 3. The certification ECU and other ECUs perform key verification via the LIN communication line. 4. The main body ECU activates the ACC cut relay. 5. The main body ECU activates the IG1 and IG2 relays. The ignition switch indicator light illuminates green. 6. The certification ECU outputs a steering UNLOCK signal. The signal is sent to the steering lock ECU via the main body ECU. 7. The main body ECU sends an engine start request signal to the ECM. 8. The ECM sends an ACC cut request signal to the main body ECU. 9. The ECM and main body ECU activate the ST relay. 10. The main body ECU deactivates the ACC cut relay until the ECU detects an engine start. 11. The ECU reactivates the ACC cut relay and turns off the ignition switch indicator light. Symbols of main body ECU STP SSW1/SSW2 ACCD IG2D STR2 STR TACH STSW ACCR Signals Stop light switch ON signal Ignition switch ON signal ACC cut relay operation signal IG2 relay operation signal ST relay operation signal Clutch switch signal (M/T) ST relay operation signal (except M/T) Engine start detection signal Starter activation request signal ACC cut request signal

124

125

126 WIRING DIAGRAM See CRANKING HOLDING FUNCTION CIRCUIT (). INSPECTION PROCEDURE 1.CHECK WHETHER ENGINE STARTS AFTER STEERING LOCK INITIALIZATION 1. Open and close the driver door when the ignition switch is off. 2. Check that the engine starts. OK: Engine starts. HINT: The engine may not start if the steering lock ECU has not been initialized through the procedure described in above after the battery runs out.

127 OK SYSTEM OK NG 2.CHECK WHETHER DTC OUTPUT RECURS 1. Clear the DTCs. HINT: After all DTCs are cleared, check if the trouble occurs again 5 seconds after the ignition switch is turned on (IG). 2. Check for DTCs again.

128 OK: No DTC is output. NG GO TO DTC CHART OK 3.CHECK SWITCH CONDITION 1. Ensure the electrical key is inside the cabin.

129 2. Check that the power source mode changes as shown below each time the ignition switch is. OK: off on (ACC) on (IG) off NG GO TO POWER SOURCE MODE DOES NOT CHANGE OK 4.CHECK BASIC FUNCTION

130 1. Ensure there is fuel in the fuel tank and the key is inside the cabin. 2. Depress the clutch pedal (M/T) or brake pedal (except M/T), and keep depressing the pedal. 3. Check that the engine cranks when the ignition switch is pressed. OK: Engine cranks. OK Go to step 8 NG

131 5.READ VALUE OF INTELLIGENT TESTER (CLUTCH START SW, PARK/NEUTRAL POSITION SW AND STOP LIGHT SW) 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester ON. 3. For except M/T: 1. Select the following menu items: Body / Main Body ECU / Data List / Stop Lamp SW1. 2. Read the display on the tester. Main body ECU: Item Stop Lamp SW1 Measurement Item/Display (Range) Stop light switch 1/ ON or OFF Normal Condition ON: Brake pedal depressed OFF: Brake pedal released Diagnostic Note OK: ON (brake pedal depressed) and OFF (brake pedal released) appear on the screen. 4. Select the following menu items: Body / Main Body ECU / Data List / N SW / C SW. 5. Read the display on the tester. - Main body ECU: Item N SW / C SW Measurement Item/Display (Range) Clutch switch (M/T) or park/ neutral position switch (except M/ T)/ ON or OFF Normal Condition ON: Clutch pedal is depressed (M/T) or Shift position is N (except M/T) Diagnostic Note -

132 OFF: Clutch pedal is released or Shift position is except N (except M/T) OK: ON (Clutch pedal is depressed (M/T) or Shift position is N (except M/T)) and OFF ( Clutch pedal is released or Shift position is except N (except M/T)) appear on the screen. NG REPAIR OR REPLACE CLUTCH START SWITCH OK

133 6.CHECK STEERING LOCK SYSTEM 1. When the ignition switch is on (ACC), check that the steering lock can be released. OK: Steering lock can be released. NG GO TO STEERING LOCK SYSTEM OK

134 7.INSPECT MAIN BODY ECU 1. Disconnect the D66 main body ECU connector. 2. Depress the clutch pedal, and keep depressing the pedal. 3. Measure the voltage when the engine cranks by pressing the ignition switch. Standard voltage: Tester Connection STSW (D66-4) - Body ground Specified Condition 10 to 14 V 4. Reconnect the main body ECU connector.

135 NG GO TO SFI SYSTEM (CRANKING HOLDING FUNCTION CIRCUIT) OK REPLACE MAIN BODY ECU 8.READ VALUE OF INTELLIGENT TESTER (L CODE CHECK) 1. Placs the electrical key is inside the vehicle. 2. Connect the intelligent tester to the DLC3. 3. Turn the ignition switch on (IG) and turn the tester ON.

136 4. Select the following menu items: Body / Certification ECU / Data List / L Code Chk. 5. Read the display on the tester. Certification ECU: Item L Code Chk Measurement Item / Display (Range) L Code Check / NG or OK OK: L code certification result is normal. Normal Condition NG: L code certification result is abnormal OK: L code certification result is normal

137 NG GO TO ENGINE IMMOBILISER SYSTEM (STEERING LOCK ECU OR ID CODE BOX MALFUNCTIONS) OK 9.READ VALUE OF INTELLIGENT TESTER (ENGINE START REQUEST) 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester ON (not start the engine). 3. Select the following menu items: Body / Certification ECU / Data List / Start Req Sig.

138 4. Read the displays on the tester. Certification ECU: Item Measurement Item / Display (Range) Normal Condition Start Req Sig OK: ST relay is ON. Starter request signal / Yes or No Yes: ST relay is ON No: ST relay is OFF

139 NO REPLACE CERTIFICATION ECU YES 10.READ VALUE OF INTELLIGENT TESTER (S CODE CHECK) 1. Connect the intelligent tester to the DLC3. 2. Turn the ignition switch on (IG) and turn the tester ON. 3. Select the following menu items: Body / Certification ECU / Data List / S Code Chk.

140 4. Read the display on the tester. Certification ECU: Item S Code Chk Measurement Item / Display (Range) S Code Check / NG or OK OK: S code certification result is normal. Normal Condition NG: S code certification result is abnormal OK: S code certification result is normal

141 NG GO TO ENGINE IMMOBILISER SYSTEM (CERTIFICATION ECU OR ID CODE BOX MALFUNCTIONS) OK REPLACE ID CODE BOX

142 ENTRY AND START SYSTEM > Engine Switch Indicator Circuit DESCRIPTION Engine start conditions or system malfunctions can be checked by observing the status of the ignition switch indicator light. Power Source Mode/Condition Ignition switch indicator light condition Clutch pedal released (M/T) Brake pedal released (except M/T) Indicator Light Condition Clutch pedal depressed (M/T) Brake pedal depressed (except M/T) Off OFF Illuminates (Green)

143 On (ACC, IG) Illuminates (Amber) Illuminates (Green) Engine running OFF OFF Steering lock not unlocked System malfunction Clutch switch malfunction (M/T) Flashes (Green) for 15 seconds Flashes (Amber) for 15 seconds Flashes (Green) for 15 seconds Flashes (Green) for 15 seconds Flashes (Amber) for 15 seconds Flashes (Green) for 15 seconds WIRING DIAGRAM

144 INSPECTION PROCEDURE 1.INSPECT IGNITION SWITCH ASSEMBLY 1. Remove the ignition switch. 2. Apply the battery voltage between the terminals of the switch, and check the illumination condition of the ignition switch indicator light. NOTICE: If the positive (+) lead and the negative (-) lead are incorrectly connected, the ignition switch indicator light does not illuminate. If the voltage is too low, the indicator light does not illuminate. OK: Measurement Condition Battery positive (+) Terminal 11 (SWIL) Battery negative (-) Terminal 4 (COM) or 5 (GND) Battery positive (+) Terminal 12 (INDS) Battery negative (-) Terminal 4 (COM) or 5 (GND) Specified Condition Illuminates Illuminates

145 Battery positive (+) Terminal 13 (INDW) Battery negative (-) Terminal 4 (COM) or 5 (GND) Illuminates 3. Reinstall the ignition switch. NG REPLACE IGNITION SWITCH ASSEMBLY OK

146 2.CHECK HARNESS AND CONNECTOR (IGNITION SWITCH - MAIN BODY ECU AND BODY GROUND) 1. Disconnect the D55 ignition switch connector. 2. Disconnect the D65 and D66 main body ECU connectors.

147 3. Measure the resistance of the wire harness side connectors. Standard resistance: Tester Connection D55-11 (SWIL) - D65-8 (SWIL) D55-12 (INDS) - D66-1 (INDS) D55-13 (INDW) - D66-8 (INDW) D55-5 (GND) - Body ground D55-4 (COM) - Body ground D55-11 (SWIL) or D65-8 (SWIL) - Body ground D55-12 (INDS) or D66-1 (INDS) - Body ground D55-13 (INDW) or D66-8 (INDW) - Body ground Specified Condition Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω Below 1 Ω 10 kω or higher 10 kω or higher 10 kω or higher 4. Reconnect the main body ECU connectors. 5. Reconnect the ignition switch connector.

148 NG REPAIR OR REPLACE HARNESS OR CONNECTOR OK REPLACE MAIN BODY ECU

149 STARTER (for 0.8 kw Type) > COMPONENTS

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155 2 / 2 STARTER (for 0.8 kw Type) > REMOVAL

156 1. REMOVE BATTERY 1. Disconnect the negative battery terminal. 2. Disconnect the positive battery terminal.

157 3. Loosen the nut, and remove the battery carrier clamp. 4. Remove the battery from the vehicle. 2. REMOVE BATTERY TRAY 3. REMOVE FLYWHEEL HOUSING SIDE COVER 1. Disengage the claw while pushing it downward and remove the flywheel housing side cover. 4. REMOVE STARTER ASSEMBLY

158 1. Separate the harness clamp. 2. Remove the bolt and remove the wire harness bracket.

159 3. Remove the terminal cap. 4. Separate the harness clamp. 5. Remove the nut and disconnect terminal Disconnect the connector. 7. Remove the 2 bolts and remove the starter assembly.

160 STARTER (for 0.8 kw Type) > DISASSEMBLY 1. REMOVE MAGNET STARTER SWITCH ASSEMBLY 1. Remove the nut, and disconnect the lead wire from the magnetic switch terminal. 2. Remove the 2 nuts holding the magnetic switch onto the starter housing.

161 3. Pull the magnetic switch and while lifting the front part of the magnetic switch, release the plunger hook from the driver lever, then remove the magnetic switch. 2. REMOVE STARTER YOKE ASSEMBLY 1. Remove the 2 through bolts and end cover.

162 2. Hold the starter drive housing in a vise between alminum plates. NOTICE: Do not overtighten the vise. 3. Remove the plate and 4 brush springs. 4. Disconnect the 4 brushes, and remove the brush holder. 5. Remove the starter yoke assembly. 3. REMOVE ARMATURE 1. Pull the armature together with the drive lever out of the starter housing.

163 2. Remove the drive lever from the armature. 4. REMOVE STARTER CLUTCH SUB-ASSEMBLY 1. Using a screwdriver, tap the inside stop collar toward the armature. 2. Using a screwdriver, pry off the snap ring. 3. Pull the stop collar and starter clutch out of the armature.

164 STARTER (for 0.8 kw Type) > INSPECTION 1. INSPECT STARTER ASSEMBLY NOTICE: Perform each of the following tests within 3 to 5 seconds.

165 1. 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. 2. Perform holding test. 1. Check that the pinion gear does not return inward after the cable of terminal C is disconnected.

166 3. Inspect the clutch pinion gear return. 1. Move the pinion gear toward the armature. 4. Perform the operation test without load. 1. Connect the field coil lead wire to terminal C. Torque: 9.8 N*m{ 100 kgf*cm, 7.2 ft.*lbf } 2. Clamp the starter in a vise.

167 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: 50A or less at 11.5 V 2. INSPECT STARTER ARMATURE ASSEMBLY 1. Check the commutator for open circuits.

168 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 starter armature assembly. 2. Check the commutator for ground. 1. Using an ohmmeter, check the resistance between the commutator and armature core. Standard resistance: 10 kω or higher If the result is not as specified, replace the starter armature assembly. 3. Check the commutator for dirt and burns on the surface. If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

169 4. Check the commutator circumference runout. 1. Place the commutator on V-blocks. 2. Using a dial indicator, measure the circumference runout. Maximum runout: 0.4 mm ( in.) If the runout is greater than the maximum, replace the starter armature assembly. 5. Using vernier calipers, measure the commutator diameter. Standard diameter: 28.0 mm ( in.) Minimum diameter: 27.0 mm ( in.)

170 If the diameter is less then the minimum, replace the starter armature assembly. 6. Using vernier calipers, measure the undercut depth of the commutator. Standard depth: 0.6 mm ( in.) Minimum depth: 0.2 mm ( in.) If the undercut depth is less then the minimum, adjust it with a hacksaw blade. 3. INSPECT STARTER YOKE ASSEMBLY

171 1. Using an ohmmeter, check the resistance between terminal C and the field coil brush lead (+). NOTICE: Check the resistance between terminal C and the 2 brush leads (+). Standard resistance: Below 1 Ω If the result is not as specified, replace the starter yoke assembly. 2. Using an ohmmeter, check the resistance between the brush lead (+) and the starter yoke. NOTICE: Check the resistance between the brush lead (-) and the starter yoke. Standard resistance: Below 1 Ω If the result is not as specified, replace the starter yoke assembly. 4. INSPECT BRUSH

172 1. Using vernier calipers, measure the brush length. Standard length: 10 mm ( in.) Minimum length: 6 mm ( in.) If the length is less than the minimum, replace the starter yoke assembly. 5. INSPECT STARTER CLUTCH SUB-ASSEMBLY 1. 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 sub-assembly.

173 6. INSPECT MAGNET STARTER SWITCH ASSEMBLY 1. 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. 2. Check the pull-in coil for an open circuit. 1. Using an ohmmeter, check the resistance between terminals 50 and C. Standard resistance: Below 1 Ω

174 If the result is not as specified, replace the magnet starter switch assembly. 3. Check whether the holding coil has an open circuit. 1. Using an ohmmeter, check the resistance between terminal 50 and the switch body. Standard resistance: Below 2 Ω If the result is not as specified, replace the magnet starter switch assembly.

175 STARTER (for 0.8 kw Type) > REASSEMBLY 1. INSTALL STARTER CLUTCH SUB-ASSEMBLY 1. Apply grease to the bushing and spline of the starter clutch. 2. Place the starter clutch and inside stop collar on the armature.

176 3. Apply grease to the snap ring, and install it onto the armature shaft groove. 4. Using a vise, compress the snap ring. 5. Hold the starter clutch, tap the armature shaft and install the stop collar onto a new snap ring with a plastic-faced hammer. 2. INSTALL STARTER ARMATURE ASSEMBLY

177 1. Apply grease to the drive lever that is in contact with the starter pivot part of the drive lever. 2. Install the drive lever onto the starter clutch. 3. Install the armature together with the drive lever onto the starter housing. 3. INSTALL STARTER YOKE ASSEMBLY 1. Align the cutout of the starter yoke assembly with the protrusion of the starter lever. 2. Hold the starter drive housing in a vice between aluminum plates. NOTICE: Do not overtighten the vise.

178 3. Install the brush holder, and connect the 4 brushes into the brush holder. 4. Install the 4 brush springs and plate. NOTICE: Check that positive (+) lead wires are not grounded. 5. Install the end cover with the 2 through bolts. Torque: 5.9 N*m{ 60 kgf*cm, 52 in.*lbf } 4. INSTALL MAGNET STARTER SWITCH ASSEMBLY

179 1. Hang the plunger of the magnetic switch onto the drive lever from the upper side. 2. Install the magnetic switch with the 2 nuts. Torque: 8.3 N*m{ 85 kgf*cm, 73 in.*lbf } 3. Connect the lead wire to the terminal, and install the nut. Torque: 9.8 N*m{ 100 kgf*cm, 87 in.*lbf }

180 STARTER (for 0.8 kw Type) > INSTALLATION 1. INSTALL STARTER ASSEMBLY

181 1. Install the starter assembly with the 2 bolts. Torque: 37 N*m{ 377 kgf*cm, 27 ft.*lbf } 2. Connect the connector. 3. Connect terminal 30 with the nut. Torque: 9.8 N*m{ 100 kgf*cm, 7.2 ft.*lbf } 4. Close the terminal cap. 5. Install the wire harness bracket with the bolt. Torque: 8 N*m{ 82 kgf*cm, 71 in.*lbf }

182 6. Install the harness clamp. 2. INSTALL FLYWHEEL HOUSING SIDE COVER 1. Insert the protruding portion into the end of the cylinder block and while pushing it along the cylinder block, fit the claw into the cylinder block. NOTICE: Make sure that the claw makes a click sound, indicating that it fits tightly. Replace the claw with a new one if it does not fit tightly or is deformed.