Inspection [09/2014 - ]: Procedure

1. Perform a pull-in test.
   1. Remove the nut, and disconnect the field coil lead wire from terminal C.

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   2. Once again, install and fasten the removed nut to the terminal C.

      HINT: 

      Make sure the contact area of the terminal C is not floating.

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   3. Connect a battery to the magnet starter switch assembly as shown in the illustration. Check that the clutch pinion gear moves outward.

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      *a	Starter Body
      *b	Terminal 50
      *c	Terminal C
      	Moves outward

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

2. Perform a hold-in test.

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   *a	Starter Body
   *b	Terminal 50
   *c	Terminal C
   	Disconnect

   1. While maintaining the battery connections of the pull-in test, disconnect the negative (-) lead from terminal C. Check that the clutch pinion gear does not return inward.

      If the clutch pinion gear returns inward, replace the magnet starter switch assembly.

3. Perform a return test.

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   *a	Starter Body
   *b	Terminal 50
   *c	Terminal C
   	Disconnect
   	Returns inward

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

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

4. Perform a no-load performance test.
   1. Remove the nut from the terminal C.

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

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

   3. Secure the starter assembly in a vise between aluminum plates.
      NOTE:

      Ensure that the starter assembly is secured in the vise to prevent it from falling out.

   4. Connect the battery and an ammeter to the starter assembly as shown in the illustration.
      NOTE:

      Do not allow any lead to get caught as the clutch pinion gear operates.

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      *a	Terminal 30
      *b	Terminal 50
      *c	Starter Body
      	Rotates

   5. Check that the starter assembly operates smoothly and steadily while the clutch pinion gear is moving outward.

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

      Standard Current

      Tester Connection	Condition	Specified Condition
      Battery positive (+) terminal - Terminal 30 - Terminal 50	11.5 V	Below 150 A

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

HINT: 

If there is no continuity between any segments, replace the starter armature assembly.

1. Check the commutator appearance.

   If the surface is dirty or burnt, restore it with sandpaper (400-grit) or on a lathe.

2. Check the commutator for an open circuit.

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   *a

   Segment

   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

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

3. Check the commutator for a short circuit.

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   *a	Segment
   *b	Starter Armature Core

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

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      Segment - Starter armature core	Always	10 kΩ or higher

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

4. Check the commutator for runout.

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   *a	Armature Shaft

   1. Place the armature shaft on V-blocks.
   2. Using a dial indicator, measure the runout.

      Maximum Runout

      0.05 mm (0.00197 in.)

      If the runout is greater than the maximum, replace the starter armature assembly.

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

   Standard Diameter

   29 mm (1.1417 in.)

   Minimum Diameter

   28 mm (1.1024 in.)

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

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6. Check that the undercut portion between the segments is free of foreign matter and measure its depth.

   Standard Undercut Depth

   0.4 mm (0.0157 in.)

   Minimum Undercut Depth

   0.2 mm (0.0079 in.)

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

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

      Standard Length

      14.4 mm (0.5669 in.)

      Minimum Length

      9.0 mm (0.3543 in.)

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

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      *a

      Length

2. Check the brush holder resistance.

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   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.

3. Check the brush spring load.
   1. Take a pull scale reading the instant the brush spring separates from the brush.

      Standard Spring Load

      22.3 to 27.3 N (2.27 to 2.78 kgf, 5.01 to 6.14 lbf)

      Minimum Spring Load

      13.8 N (1.41 kgf, 3.10 lbf)

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

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1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.

   If worn or damaged, replace the gear or clutch assembly. Also check the drive plate ring gear for wear or damage.

2. 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.

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   *a	Free
   *b	Lock

   If the clutch pinion gear does not operate as specified, replace the starter center bearing clutch sub-assembly.

1. Check the plunger.

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   1. Push in the plunger and check that it returns quickly to its original position.

      If the plunger does not operate as specified, replace the magnet starter switch assembly.

2. Check the pull-in coil for an open circuit.

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   *a	Terminal 50
   *b	Terminal C

   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

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

3. Check the holding coil for an open circuit.

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   *a	Terminal 50
   *b	Magnet Starter Switch Assembly Body

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

      Standard Resistance

      Tester Connection	Condition	Specified Condition
      Terminal 50 - Magnet starter switch assembly body	Always	Below 2 Ω

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