Starter (For 1.7 Kw Type) Inspection

Mount the starter in a vise between aluminum plates.

Perform a 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 moves outward.
   

   Text in Illustration

   *1	Terminal 50
   *2	Terminal C
   	Moves outward

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

Perform a holding test.

1. Disconnect the negative (-) terminal lead from terminal C with the condition specified in the pull-in test above being maintained. Check that the pinion gear remains out.
   

   Text in Illustration

   *1	Terminal C
   	Disconnect

   If the clutch pinion gear returns 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.
   

   Text in Illustration

   	Disconnect
   	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 lead wire to terminal C.
   

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}





2. Connect the battery and an ammeter to the starter as shown in the illustration.
   

   Text in Illustration

   *1	Terminal 30
   *2	Terminal 50

3. 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 dirt and/or burns on the surface.
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 Connector	Condition	Specified Condition
   Segment - Segment	Always	3.0 to 3.3 Ω

   Text in Illustration

   *1

   Segment

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

Inspect the commutator for short circuit.

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

   Standard Resistance:

   Tester Connector	Condition	Specified Condition
   Segment - Coil Core	Always	10 kΩ or higher

   Text in Illustration

   *1	Segment
   *2	Coil Core

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

Check the commutator circle runout.

1. Place the commutator on V-blocks.
   

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

   Standard circle runout:

   0.02 mm (0.000787 in.)
   

   Maximum circle runout:

   0.04 mm (0.00157 in.)
   

   If the circle runout is more than the maximum, correct the circle runout with sandpaper (No. 400) or replace the starter armature assembly.
   

Check the commutator diameter.

1. Using a vernier caliper, measure the commutator diameter.
   

   Standard diameter:

   32.2 mm (1.27 in.)
   

   Minimum diameter:

   31.1 mm (1.22 in.)
   

   Text in Illustration

   *1

   Diameter

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

Check the undercut depth.

1. 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.)
   

   If the undercut depth is less than the minimum, replace the starter armature assembly.
   

Check the brush length.

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

   Standard length:

   11.3 mm (0.445 in.)
   

   Minimum length:

   7.5 mm (0.295 in.)
   

   Text in Illustration

   *1

   Length

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

Inspect the brush insulation.

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

   Standard Resistance:

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

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

Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.

Text in Illustration

	Free
	Lock

Check the plunger.

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

   Text in Illustration

   *1	Switch Body
   *2	Spring
   *3	Plunger





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 resistance.

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 50
   *2	Terminal C

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

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

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
   *2	Switch Body

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