Starter Inspection

Perform the pull-in test.

1. Disconnect the lead wire from terminal C.
   





2. Connect the battery to the magnetic switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.
   If the clutch pinion gear does not move outward, replace the repair service starter kit.
   

Perform the holding test.

1. Maintain the battery connections of the pull-in test above, but disconnect the negative (-) terminal lead from terminal C. Check that the pinion gear remains out.
   If the clutch pinion gear returns inward, replace the repair service starter kit.
   

Inspect clutch pinion gear return test.

1. Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear moves inward.
   If the clutch pinion gear does not move inward, replace the repair service starter kit.
   

Perform the no-load performance test.

1. Connect the lead wire to terminal C with the nut. Make sure that the lead is not grounded.
   

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

2. Clamp the starter in a vise.
   

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 extender, and check that the ammeter reads the specified current.
   

   Standard current:

   90 A or less at 11.5 V
   If the test result is not as specified, overhaul the starter assembly.
   

Check the plunger.

1. Push in the plunger and check that it returns quickly to its original position.
   If necessary, replace the repair service starter kit.
   

Inspect the resistance of the pull-in coil.

1. Measure the resistance between terminals 50 and C.
   

   Standard resistance:

   Below 1 Ω
   

   If the result is not as specified, replace the repair service starter kit.
   

Inspect the resistance of the hold-in coil.

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

   Standard resistance:

   Below 2 Ω
   

   If the result is not as specified, replace the repair service starter kit.
   

Check the commutator for contamination and burns on its surface.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.

Inspect the resistance of the commutator.

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

   Standard resistance:

   Below 1 Ω
   

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




2. Measure the resistance between the commutator and armature coil core.
   

   Standard resistance:

   10 kΩ or higher
   

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

Using a vernier caliper, measure the commutator's length.

Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

Using a vernier caliper, measure the brush length.

Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.158 in.)

Check the resistance.

1. Measure the resistance between the positive (+) and negative (-) brushes.
   

   Standard resistance:

   10 kΩ or higher
   

   If the result is not as specified, repair or replace the starter commutator end frame assembly.
   

Check the starter clutch.

1. Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks.
   If necessary, replace the starter drive housing assembly.