Starter (For 1.6 Kw Type) Inspection

Mount the starter in a vise between aluminum plates.

Perform a pull-in test.

1. Remove the nut and disconnect the lead wire from terminal C.
   





2. Connect the battery to the starter as shown in the illustration. Check that the clutch pinion gear moves outward.
   

   Text in Illustration

   *1	Terminal C
   *2	Terminal 50
   	Moves outward

   If the clutch pinion gear does not move, replace the repair service starter kit.
   

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
   *2	Terminal 50
   	Disconnect

   If the clutch pinion gear moves inward, replace repair service starter kit.
   

Inspect clutch pinion gear return.

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

   Text in Illustration

   *1	Terminal 50
   	Disconnect
   	Returns inward

   If the clutch pinion gear does not return inward, replace the repair service starter kit.
   

Perform an operation test without load.

1. Connect the lead wire to terminal C.
   

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

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

   Text in Illustration

   *1	Terminal 50
   *2	Terminal 30

3. Check that the starter rotates smoothly and steadily while the pinion gear is moving out. 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 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 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 - Coil core	Always	10 kΩ or higher

   Text in Illustration

   *1	Coil Core
   *2	Segment

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

Using a vernier caliper, measure the protrusion length.

Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

Check the brush length.

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

   Standard exposed length:

   9.0 mm (0.354 in.)
   

   Minimum exposed length:

   4.0 mm (0.157 in.)
   

   Text in Illustration

   *1

   Length

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

Check the resistance.

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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Positive (+) brush - Negative (-) brush	Always	10 kΩ or higher

   If the result is not as specified, repair or replace the commutator end frame 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 center bearing clutch sub-assembly.

Check the starter center bearing clutch pinion gear.

1. Hold the starter center bearing clutch, rotate the pinion gear clockwise and check that pinion gear turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
   

   Text in Illustration

   	Free
   	Lock

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




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

   Standard Resistance:

   Tester Connection	Condition	Specified Condition
   Terminal 50 - Repair service starter kit body	Always	Below 2 Ω

   Text in Illustration

   *1	Terminal 50
   *2	Repair Service Starter Kit Body

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