Starter Inspection

Perform a 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.
   

   Text in Illustration

   *1	Terminal C
   *2	Terminal 50

   If the clutch pinion gear does not move outward, replace the magnet starter switch assembly.
   

Perform a holding test.

1. When the battery is connected as above with the clutch pinion gear out, disconnect the negative (-) terminal lead from terminal C. Check that the pinion gear remains out.
   

   Text in Illustration

   *1	Terminal C

   If the clutch pinion gear moves inward, replace the magnet starter switch assembly.
   

Inspect the 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.
   

Perform an operation test without load.

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

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*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 30
   *2	Terminal 50

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

   Standard current:

   150 A or less at 11.5 V
   

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

Check if the pull-in 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 - Terminal C	Always	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 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 - Switch body	Always	Below 2 Ω

   Text in Illustration

   *1	Terminal 50

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

Check the surface of the commutator for dirt and burns.
If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe.
If necessary, replace the starter armature assembly.

Inspect the commutator for an open circuit.

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

   Text in Illustration

   *1

   Segment

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

Inspect the commutator for a short circuit.

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

   Standard Resistance:

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

   Text in Illustration

   *1	Armature Coil Core
   *2	Commutator

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

Check the commutator circle runout.

1. Place the armature shaft on V-blocks.
   

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

   Maximum runout:

   0.05 mm (0.00197 in.)
   

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

Using a vernier caliper, measure the commutator diameter.

Standard diameter:

29.0 mm (1.14 in.)

Minimum diameter:

28.0 mm (1.10 in.)

HINT:

Be sure to measure the commutator diameter at the ridges.

Check that the undercut portion is clean and free of foreign matter. Smooth out the edge.

Standard undercut depth:

0.4 mm (0.0157 in.)

Minimum undercut depth:

0.2 mm (0.00787 in.)

HINT:

Be sure to measure the commutator undercut depth at a cutout.

Using a vernier caliper, measure the brush length.

Standard length:

14.4 mm (0.567 in.)

Minimum length:

9.0 mm (0.354 in.)

HINT:

Be sure to measure the brush lengths at the protrusions.

Inspect the load of the brush spring.

1. Take a pull scale reading immediately after the brush spring separates from the brush.
   

   Standard spring load:

   22 to 27 N (2 to 3 kgf, 5.0 to 6.1 lbf)
   

   Minimum spring load:

   14 N (1 kgf, 3.1 lbf)
   

   Text in Illustration

   *1	Brush
   *2	Brush Spring

   If the load is less than the minimum, replace the starter brush holder assembly.
   

Check the gear teeth on the planetary gears, and the internal gear and pinion gear of the starter center bearing clutch for wear or damage.
If any of the gears is damaged, replace the gear or starter center bearing clutch sub-assembly.

Hold the starter clutch, 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