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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  3 - 5	Battery voltage not applied to terminals 1 and 2	10 kΩ or higher
  	Battery voltage applied to terminals 1 and 2	Below 1 Ω

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

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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  3 - 5	Battery voltage not applied to terminals 1 and 2	10 kΩ or higher
  	Battery voltage applied to terminals 1 and 2	Below 1 Ω

If the result is not as specified, replace the glow relay.

Install the ignition switch with the 2 screws.

Connect the ignition switch connector and attach the wire harness clamp.

Attach the 2 claws to install the lower steering column cover.

Install the 2 screws.

• УКАЗАНИЕ:

• Turn the steering wheel to the right and left as necessary to install the 2 screws.

Измерьте сопротивление в соответствии со значениями, приведенными в таблице ниже.

• Номинальное сопротивление:

• Контакты для подключения диагностического прибора	Положение переключателя	Заданные условия
  Все комбинации всех контактов	LOCK	10 кОм или более
  2 (AM1) - 3 (ACC)	ACC	Менее 1 Ом
  2 (AM1) - 3 (ACC) 2 (AM1) - 4 (IG1) 6 (IG2) - 7 (AM2)	ON (ВКЛ)	Менее 1 Ом
  1 (ST1) - 2 (AM1) 1 (ST1) - 4 (IG1) 6 (IG2) - 7 (AM2) 6 (IG2) - 8 (ST2)	START	Менее 1 Ом

Если результат проверки не соответствует заданному, замените замок зажигания в сборе.

Remove the 2 screws.

• УКАЗАНИЕ:

• Turn the steering wheel to the right and left as necessary to remove the 2 screws.

Detach the 2 claws and remove the lower steering column cover.

Disconnect the ignition switch connector and detach the wire harness clamp.

Remove the 2 screws and ignition switch.

Install the starter with the 2 bolts and nut.

• Момент затяжки:
• 68 N*m{ 693 kgf*cm, 50 ft.*lbf}

Connect the starter wire with the nut.

• Момент затяжки:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Connect the starter connector.

Connect the clutch flexible hose bracket with the bolt.

• Момент затяжки:
• 72 N*m{ 730 kgf*cm, 53 ft.*lbf}

Connect the release cylinder with the 2 bolts.

• Момент затяжки:
• 12 N*m{ 120 kgf*cm, 9 ft.*lbf}

Install the rear engine under cover with the 4 bolts.

• Момент затяжки:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Using a press, install the starter armature assembly.

Align the claw of the brush holder with the claw groove of the starter yoke.

Place the brush holder on the starter yoke.

Connect the 4 brushes to the starter brush holder.

Apply high-temperature grease to the starter idle pinion, starter clutch, starter armature pinion, retainer and clutch roller.

Insert the steel ball into the starter clutch hole.

Insert the return spring into the starter clutch hole.

Install the starter clutch, idle gear, retainer and clutch roller to the starter drive housing.

Install the starter housing to the magnet starter switch with the 2 screws.

• Момент затяжки:
• 9.3 N*m{ 95 kgf*cm, 82 in.*lbf}

Install a new O-ring to the groove of the starter yoke.

Align the claw of the starter brush holder with the grooves of the magnet starter switch.

Install the 2 new O-rings to the bolts.

Install the 2 bolts.

• Момент затяжки:
• 13 N*m{ 130 kgf*cm, 9 ft.*lbf}

Connect the terminal C wire with the nut.

• Момент затяжки:
• 5.9 N*m{ 60 kgf*cm, 52 in.*lbf}

Install the terminal 50 wire with the screw.

• Момент затяжки:
• 3.6 N*m{ 37 kgf*cm, 32 in.*lbf}

Mount the starter in a vise between aluminum plates.

Perform a pull-in test.

Remove the nut, and then disconnect the lead wire from terminal C.

Connect the battery to the magnet starter switch as shown in the illustration. Check that the clutch pinion gear extends.

Text in Illustration

*1	Terminal C
*2	Terminal 50

If the clutch pinion gear does not move, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Perform a holding test.

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 extended.

Text in Illustration

*1	Terminal C

If the clutch pinion gear returns inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Inspect the clutch pinion gear return.

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

If the clutch pinion gear does not return inward, inspect the magnet starter switch assembly. If the magnet starter switch assembly is not as specified, replace it.

Perform an operation test without load.

Connect the field coil lead wire to terminal C.

• Момент затяжки:
• 5.9 N*m{ 60 kgf*cm, 52 in.*lbf}

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

Text in Illustration

*1	Terminal 30
*2	Terminal 50

Check that the starter rotates smoothly and steadily while the pinion gear is extended. Then measure the current.

• Specified current:
• 120 A or less at 11.5 V

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

• УКАЗАНИЕ:

• Inspect the starter brush holder assembly, starter yoke assembly and starter armature assembly. If there is a malfunction, replace the part and perform this test again.

Inspect the pull-in coil.

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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Terminal C - Terminal 50	Always	Below 1 Ω

Text in Illustration

*1	Terminal C
*2	Terminal 50

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

Inspect the holding coil.

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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Switch body - Terminal 50	Always	Below 2 Ω

Text in Illustration

*1	Switch Body
*2	Terminal 50

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

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

• Standard Resistance:

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

Check the brush spring load.

Take a pull scale reading immediately after the brush spring separates from the brush.

• Standard spring load:
• 27 to 32 N (2.7 to 3.3 kgf, 6.0 to 7.3 lbf)

• Minimum spring load:
• 18 N (2 kgf, 4.0 lbf)

Text in Illustration

*1	Brush Spring
*2	Brush

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

Inspect for an open circuit.

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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Lead wire - Brush	Always	Below 1 Ω

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

Inspect for a short circuit.

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

• Standard Resistance:

• Tester Connection	Condition	Specified Condition
  Starter yoke body - Brush	Always	10 kΩ or higher

If the result is not as specified, replace the starter yoke 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. Replace the armature if necessary.

Inspect the commutator for an open circuit.

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.

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	Segment
*2	Coil Core

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

Inspect the commutator circle runout.

Place the armature on V-blocks.

Using a dial indicator, measure the circle runout.

• Maximum circle runout:
• 0.05 mm (0.00197 in.)

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

Using a vernier caliper, measure the commutator diameter.

• Standard diameter:
• 35.0 mm (1.38 in.)

• Minimum diameter:
• 34.0 mm (1.34 in.)

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

Measure the undercut depth of the commutator.

• Standard depth:
• 0.7 mm (0.0276 in.)

• Minimum depth:
• 0.2 mm (0.00787 in.)

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

Inspect the bearings.

Rotate the pinion gear clockwise and check that it 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 clutch sub-assembly.

Turn the pinion gear by hand while applying inward force and check the movement of the bearing.

If resistance is felt or the bearing sticks, replace the starter clutch sub-assembly.

Remove the screw and terminal 50 wire.

Remove the nut and disconnect the terminal C wire.

Remove the 2 through bolts and O-rings and pull out the starter yoke with the armature.

Remove the 2 screws and magnet starter switch.

Remove the return spring.

Remove the starter clutch, starter armature pinion, starter idle pinion, retainer and clutch roller from the starter drive housing.

Using a magnet hand, remove the steel ball from the clutch shaft hole.

Disconnect the 4 brushes from the starter brush holder.

Remove the starter brush holder.

Using a plastic-faced hammer, tap the end of the starter yoke and remove the starter armature.

Remove the 4 bolts and rear engine under cover.

Remove the 2 bolts and disconnect the release cylinder.

Remove the bolt and disconnect the clutch flexible hose bracket.

Disconnect the starter connector.

Remove the terminal cap.

Remove the nut and disconnect the starter wire.

Remove the nut, 2 bolts and starter.