Starter 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 repair service starter kit.
   

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 repair service starter kit.
   

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 repair service starter kit.
   

Perform operation test without load.

1. Connect the 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.
   





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 11.5 V
   

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

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.

Check the resistance.

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 each segment of 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 depth indicated in the illustration.

Standard depth:

3.1 mm (0.122 in.)

Maximum depth:

3.8 mm (0.150 in.)

Check the brush length.

1. Using a vernier caliper, measure the brush length.
   

   Standard length:

   9.0 mm (0.354 in.)
   

   Minimum length:

   4.0 mm (0.158 in.)
   

   If the length is less than the minimum, replace the starter commutator end frame assembly.
   

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, replace the starter commutator end frame assembly.
   

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

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 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 repair service starter kit.
   

Check the resistance.

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

   Standard resistance:

   Below 1 Ω
   

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




2. Measure the resistance between terminal 50 and the repair service starter kit body.
   

   Standard resistance:

   Below 2 Ω
   

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