Starter (For 1.0 Kw Type) Inspection

Perform a pull-in test.

1. Remove the nut and disconnect the lead wire from terminal C.
   





2. Connect the battery to the starter magnetic switch as shown in the illustration. Check that the clutch pinion gear is extended.
   If the clutch pinion gear does not move, replace the magnet starter switch assembly.
   

Perform a hold-in 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 returns inward, replace the magnet starter switch assembly.
   

Check the operation.

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

Perform operation test without load.

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

   Torque:

   9.8 N*m{100 kgf*cm, 87 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.
   

4. Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current.
   

   Standard Current:

   Tester Connection	Condition	Specified Condition
   Battery positive terminal - Terminal 30	11.5 V	Below 90 A

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

Check the commutator for open circuits.

1. Measure the resistance according to the value(s) in the table below.
   

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Segment - Segment	Always	Below 1 Ω

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

Check the commutator for ground.

1. Measure the resistance according to the value(s) in the table below.
   

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Commutator - Armature core	Always	10 kΩ or higher

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

Check the commutator surface for dirt and burns.
If the surface is dirty or burnt, restore it with sandpaper (No. 400) or a lathe.

Check the commutator for circle runout.

1. Place the commutator on V-blocks.
   

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

   Maximum runout:

   0.05 mm (0.00196 in.)
   

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

Using a vernier caliper, measure the commutator diameter.

Standard diameter:

28.0 mm (1.10 in.)

Minimum diameter:

27.0 mm (1.06 in.)

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 (0.00787 in.)

Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
Terminal C - Brush lead	Always	Below 1 Ω

Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
Brush lead - Body	Always	10 kΩ or higher

Using a vernier caliper, measure the brush length.

Standard length:

14.0 mm (0.551 in.)

Minimum length:

9.0 mm (0.354 in.)

Measure the resistance according to the value(s) in the table below.

Standard Resistance:

Tester Connection	Condition	Specified Condition
Positive (+) brush holder - Negative (-) brush holder	Always	10 kΩ or higher

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 the result is not as specified, replace the starter clutch sub-assembly.

Check the plunger.

1. Push in the plunger and check that it returns quickly to its original position.
   If the result is not as specified, replace the magnet starter switch assembly.
   

Check the pull-in coil for open circuits.

1. Measure the resistance according to the value(s) in the table below.
   

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Terminal 50 - Terminal C	Always	Below 1 Ω

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

Check whether the holding coil has an open circuit.

1. Measure the resistance according to the value(s) in the table below.
   

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Terminal 50 - Body	Always	Below 2 Ω

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