Starter (For Denso Made) Inspection

Perform pull-in test.

1. Remove the nut, and then disconnect the field coil lead wire from terminal C.
   





2. Connect the battery to the magnet starter switch as shown in the illustration. Then check that the clutch pinion gear moves outward.
   If the clutch pinion gear does not move, replace the magnet starter switch assembly.
   
   

   
   
   
   
   

   Text in Illustration

   *1

   Operation

   -

   -

Perform holding test.

1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) lead from terminal C. Check that the pinion gear remains out.
   If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
   
   

   
   
   
   
   

   Text in Illustration

   *1

   Terminal C

   *a

   Disconnect

Inspect clutch pinion gear return.

1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
   If the clutch pinion gear does not return inward, replace the magnet starter switch assembly.
   
   

   
   
   
   
   

   Text in Illustration

   *a

   Operation

   *b

   Disconnect

Perform operation test without load.

1. Connect the field coil lead wire to terminal C with the nut.
   

   Torque:

   5.9 N*m{60 kgf*cm, 52 in.*lbf}

2. Mount the starter in a vise between aluminum plates.
   





3. Connect the battery and an ammeter to the starter as shown in the illustration.
   
   

   
   
   
   
   

   Text in Illustration

   *1	Terminal 50	*2	Terminal 30
   *a	Connect	-	-

4. Check that the starter rotates smoothly and steadily while the pinion gear is moving outward. Then measure the current.
   

   Standard current:

   100 A or less at 11.5 V
   

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

Measure the resistance.

1. Measure the resistance between any 2 segments of the commutator.
   

   Standard resistance:

   Below 1 Ω
   

   Text in Illustration

   *1

   Segment

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




2. Measure the resistance between each segment of the commutator and the armature coil core.
   

   Standard resistance:

   10 kΩ or higher
   

   Text in Illustration

   *1	Segment
   *2	Armature Coil Core

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

Inspect circle runout.

1. Place the armature on V-blocks.
   

2. Using a dial gauge, measure the circle runout.
   

   Maximum circle runout:

   0.05 mm (0.000197 in.)
   

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

Using a vernier caliper, measure the commutator diameter.

Standard commutator diameter:

35.0 mm (1.38 in.)

Minimum commutator diameter:

34.0 mm (1.34 in.)

Measure the undercut depth of the commutator.

Standard undercut depth:

0.7 mm (0.0276 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

Inspect the armature bearings.

1. Check that the armature bearings rotate smoothly.
   If the result is not as specified, replace the stater armature assembly.
   

Inspect the field coil for an open circuit.

1. Measure the resistance between the lead wire and field coil brush lead.
   

   Standard resistance:

   Below 1 Ω
   

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

Inspect the shunt coil for an open circuit.

1. Measure the resistance between the shunt coil terminals.
   

   Standard resistance:

   1.5 to 1.9 Ω at 20°C (68°F)
   

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

Using a vernier caliper, measure the brush length.

Standard length:

15.0 mm (0.591 in.)

Minimum length:

9.0 mm (0.354 in.)

Inspect the brush insulation.

1. Using an ohmmeter, measure the resistance between the positive and negative brush holders.
   

   Standard resistance:

   10 kΩ or higher
   

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

Take a pull scale reading the instant the brush spring separates from the brush.

Standard spring load:

22 to 28 N (2 to 3 kgf, 4.8 to 6.2 lbf)

Minimum spring load:

13 N (1 kgf, 2.9 lbf)

Rotate the pinion gear clockwise and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.

Text in Illustration

	Free
	Lock

Check if the pull-in coil has an open circuit.

1. Measure the resistance between terminal 50 and terminal C.
   

   Standard resistance:

   Below 1 Ω
   

   Text in Illustration

   *1	Terminal C
   *2	Terminal 50

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

Check if the hold-in coil has an open circuit.

1. Measure the resistance between terminal 50 and the switch body.
   

   Standard resistance:

   Below 2 Ω
   

   Text in Illustration

   *1	Terminal 50

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