Starter Inspection

Perform the pull-in test.

1. Disconnect the field coil lead wire from terminal C.
   

2. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward.
   

Perform the 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.
   

Inspect the clutch pinion gear return.

1. Disconnect the negative (-) lead from the starter body. Check that the clutch pinion gear returns inward.
   

Perform the operation test without load.

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

   Torque:

   5.9 N*m{60 kgf*cm, 52 in.*lbf}

2. Grip the starter in a vise.
   

3. Connect the battery and ammeter to the starter as shown.
   

4. Check that the ammeter displays the specified current.
   

   Specified current:

   120 A or less at 11.5 V
   

Inspect the commutator for an open circuit.

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

   Standard resistance:

   Below 1 Ω
   

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

Inspect the commutator for a short circuit.

1. Using an ohmmeter, check that there is no resistance between the commutator and armature core.
   

   Standard resistance:

   10 kΩ or higher
   

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

Inspect the commutator circle runout.

1. Place the armature on the V-blocks.
   

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

   Maximum circle runout:

   0.05 mm (0.0020 in.)
   

   1. If the runout is greater than the maximum, correct it with sandpaper (#400) or replace the armature assembly.
      

Using a vernier caliper, measure the commutator diameter.

Standard diameter:

35.0 mm (1.378 in.)

Minimum diameter:

34.0 mm (1.339 in.)

1. If the diameter is less than the minimum, replace the armature assembly.
   

Measure the undercut depth of the commutator.

Standard depth:

0.7 mm (0.028 in.)

Minimum depth:

0.2 mm (0.008 in.)

1. If the undercut depth is less than the minimum, correct it with a hacksaw blade.
   

Inspect the bearings.

1. Check that the bearings rotate smoothly.
   If necessary, replace them.
   

Inspect for an open circuit.

1. Measure the resistance between the terminal C wire and brushes.
   

   Standard resistance:

   Below 1 Ω
   

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

Inspect for a short circuit.

1. Measure the resistance between the terminal C wire and starter yoke body.
   

   Standard resistance:

   10 kΩ or higher
   

2. Measure the resistance between the brushes and starter yoke body.
   

   Standard resistance:

   10 kΩ or higher
   

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

Using a vernier caliper, measure the brush length.

Standard brush length:

16.5 mm (0.650 in.)

Minimum brush length:

9.0 mm (0.354 in.)

1. If the length is less than the minimum, replace the brush holder and starter yoke assembly.
   

Measure the resistance between the positive and negative brush holders.

Standard resistance:

10 kΩ or higher

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

Using a pull scale, measure the brush spring load.

Standard spring load:

26.5 to 32.3 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)

Minimum spring load:

17.6 N (1.8 kgf, 4.0 lbf)

1. If the spring load is less than the minimum, replace the brush holder.
   

Check that the starter clutch cannot be rotated counterclockwise, and can be rotated clockwise.

1. If the starter clutch is not as specified, replace it.
   

Inspect the pull-in coil.

1. Measure the resistance between terminals 50 and C.
   

   Standard resistance:

   Below 1 Ω
   

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

Inspect the hold-in coil.

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

   Standard resistance:

   Below 2 Ω
   

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