Page 2977 of 3051
Trouble DiagnosesNLSC0018If any abnormality is found, immediately disconnect battery negative terminal.
SEL761W
STARTING SYSTEM
Trouble Diagnoses
SC-16
Page 2978 of 3051
ConstructionNLSC0006
SEL027UC
NEL772
STARTING SYSTEM
Construction
SC-17
Page 2979 of 3051
MEL136L
YEL420B
STARTING SYSTEM
Construction (Cont’d)
SC-18
Page 2980 of 3051
NEL791
NEL642
NEL643
Removal and InstallationNLSC0007REMOVALNLSC0007S011. Remove intake air duct and air cleaner assembly.
2. Disconnect starter harness.
3. Remove starter bolts (two).
4. Remove starter.
STARTING SYSTEM
Construction (Cont’d)
SC-19
Page 2981 of 3051

NEL644
INSTALLATIONNLSC0007S02To install, reverse the removal procedure.
MEL138L
InspectionNLSC0019MAGNETIC SWITCH CHECKNLSC0019S01+Before starting to check, disconnect battery ground cable.
+Disconnect“M”terminal of starter motor.
1. Continuity test (between“S”terminal and switch body).
+No continuity ... Replace.
2. Continuity test (between“S”terminal and“M”terminal).
+No continuity ... Replace.
MEL139L
PINION/CLUTCH CHECKNLSC0019S021. Inspect pinion teeth.
+Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
+Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
+If it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.
SEL014Z
BRUSH CHECKNLSC0019S03BrushNLSC0019S0301Check wear of brush.
Wear limit length:
Refer to SDS (SC-34).
+Excessive wear ... Replace.
STARTING SYSTEM
Removal and Installation (Cont’d)
SC-20
Page 2982 of 3051
SEL015Z
Brush Spring CheckNLSC0019S0302Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS (SC-34).
+Not within the specified values ... Replace.
SEL016Z
Brush HolderNLSC0019S03031. Perform insulation test between brush holder (positive side)
and its base (negative side).
+Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
+If brush holder is bent, replace it; if sliding surface is dirty,
clean.
SEL018Z
YOKE CHECKNLSC0019S04Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunction-
ing parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.
STARTING SYSTEM
Inspection (Cont’d)
SC-21
Page 2983 of 3051
SEL019Z
ARMATURE CHECKNLSC0019S051. Continuity test (between two segments side by side).
+No continuity ... Replace.
2. Insulation test (between each commutator bar and shaft).
+Continuity exists. ... Replace.
SEL020Z
3. Check commutator surface.
+Rough ... Sand lightly with No. 500 - 600 emery paper.
SEL021Z
4. Check diameter of commutator.
Commutator minimum diameter:
Refer to SDS (SC-34).
+Less than specified value ... Replace.
SEL022Z
5. Check depth of insulating mold from commutator surface.
+Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
STARTING SYSTEM
Inspection (Cont’d)
SC-22
Page 2984 of 3051
AssemblyNLSC0020Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
SEL026Z
PINION PROTRUSION LENGTH ADJUSTMENTNLSC0020S01Clearance (QG & SR engine models)NLSC0020S0101With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance“!”between the front edge
of the pinion and the pinion stopper.
Clearance“!”:
Refer to SDS (SC-34).
MEL140L
Movement (YD engine models)NLSC0020S0102Compare movement“!”in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement“!”:
Refer to SDS, (SC-34).
SEL633BA
+Not in the specified value ... Adjust by adjusting plate.
STARTING SYSTEM
Assembly
SC-23