Starter Inspection

Perform pull-in test:

1. Disconnect the wire from terminal C.
   





2. Connect the battery to the magnetic switch as shown in the illustration. Check that the clutch pinion gear moves outward.
   If the clutch pinion gear does not move outward, replace the repair service starter kit.
   

Perform hold-in test:

1. Disconnect the negative (-) terminal lead from terminal C under condition pull-in test. 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 moves inward.
   If the clutch pinion gear does not move inward, replace the repair service starter kit.
   

Perform no-load performance test:

1. Connect the wire to terminal C with the nut. Make sure that the lead is not grounded.
   

   Torque:

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





2. Clamp the starter in a vise.
   

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

4. Check that the starter rotates smoothly and steadily with the clutch pinion gear remaining out. Check that the ammeter reads the specified current.
   

   Specified current:

   Condition	Specified condition
   at 11.5 V	90 A or less

   If the current is not as specified, overhaul the starter.
   

Inspect the resistance of the commutator.

1. Using an ohmmeter, measure the resistance between the segments of the commutator.
   

   Standard resistance:

   Tester connection	Specified condition
   Segment - Segment	Below 1 Ω

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




2. Using an ohmmeter, measure the resistance between the commutator and armature coil core.
   

   Standard resistance:

   Tester connection	Specified condition
   Commutator - Armature	10 kΩ or higher

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

Check the surface of the commutator for dirt or burn.
If the surface is dirty or burnt, smooth it with 400-grit sandpaper or trim it on a lathe.

Using vernier calipers, measure the commutator length.

Standard length:

3.1 mm (0.122 in.)

Maximum length:

3.8 mm (0.150 in.)

Using vernier calipers, measure the brush length.

Standard length:

9.0 mm (0.354 in.)

Minimum length:

4.0 mm (0.158 in.)

Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.

Standard resistance:

Tester connection	Specified condition
Positive (+) brush - Negative (-) brush	10 kΩ or higher

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

Check the starter clutch pinion gear.

1. Turn the clutch pinion gear clockwise and check that it turns freely. Try to turn the clutch pinion gear counterclockwise and check that it locks.
   If necessary, replace the center bearing clutch sub-assembly.
   

Check the plunger.

1. Push in the plunger and check that it returns quickly to its original position.
   If necessary, replace the repair service starter kit.
   

Using an ohmmeter, measure the resistance between terminals 50 and C.

Standard resistance:

Tester connection	Specified condition
Terminal 50 - Terminal C	Below 1 Ω

Using an ohmmeter, measure the resistance between terminal 50 and the switch body.

Standard resistance:

Tester connection	Specified condition
Terminal 50 - Switch body	Below 2 Ω