Starter Inspection

Perform pull-in test.

1. Remove the nut, and then disconnect the 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 move outward.
   If the clutch pinion gear does not move, replace the magnet starter switch.
   

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 returns out.
   If the clutch pinion gear returns inward, replace the magnet starter switch.
   

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.
   

Perform operation test without load.

1. Connect the lead wire to terminal C.
   

   Torque:

   8.0 N*m{82 kgf*cm, 71 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 while the pinion gear is moving outward. Then measure the current.
   

   Standard current:

   90 A or less at 10.9 V
   

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

Check the commutator for an open circuit.

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

   Standard resistance:

   2.7 to 3.3 Ω
   

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

Check the commutator for a short to ground.

1. Measure the resistance between the commutator and armature core.
   

   Standard resistance:

   10 kΩ or higher
   

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

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

Check the commutator circle runout.

1. Place the commutator on V-blocks.
   

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

   Standard runout:

   0.02 mm (0.0008 in.)
   

   Maximum runout:

   0.04 mm (0.0016 in.)
   

   If the runout is greater than the maximum, replace the armature assembly.
   

Using a vernier caliper, measure the commutator diameter.

Standard diameter:

32.2 mm (1.2677 in.)

Minimum diameter:

31.1 mm (1.2244 in.)

Using a vernier caliper, measure the undercut depth of the commutator.

Standard depth:

0.9 mm (0.0354 in.)

Minimum depth:

0.4 mm (0.0157 in.)

Using a vernier caliper, measure the brush length.

Standard length:

11.3 mm (0.4449 in.)

Minimum length:

7.5 mm (0.2953 in.)

Check the brush holder.

1. Measure the resistance between the brushes.
   

   Standard resistance:

   Tester Connection	Specified Condition
   A - B	10 kΩ or higher
   A - C	10 kΩ or higher
   A - D	Below 1 Ω
   B - C	Below 1 Ω
   B - D	10 kΩ or higher
   C - D	10 kΩ or higher

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

Check the starter clutch pinion gear.

1. 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. Install the plunger and spring onto the switch body.
   





2. 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 an open circuit.

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

   Standard resistance:

   Below 1 Ω
   

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

Check the holding coil for an open circuit.

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 magnet starter switch assembly.