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STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTIONM1162001100205
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move
out.
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge.
Standard value: 0.5 − 2.0 mm5. If the pinion gap is out of specification, adjust by
adding or removing gasket(s) between the
magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
AK300648AB
<4G1>
Switch
S
M
Wire
Battery Starter
motor B
AKX01238
<4G6>
B MS
batterySwitch
Starter
motorWire
AG
AKX00198
Stopper
Pinion gap Pinion
AC
AKX00199
AK300649AB
<4G1>
S
M
Wire
Battery Starter
motor B
AKX01242
<4G6>
S
B M
Battery
Starter
motorWire
AF
Page 88 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-24
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with
soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and
carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the
starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery cable from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
AK300650AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01244
<4G6>
S
B M
Battery
Starter
motorWire
AF
AK300651AB
<4G1>
S
A M
V BCarbon-pile rheostat
Battery
VoltmeterAmmeter
Starter
motor
AKX01246
<4G6>
S
M
BAmmeter
Carbon-pile
rheostat
Battery
Starter
motor
Voltmeter
AF
A
V
Page 89 of 788
STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal
and body.
WARNING
Be careful not to get your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.
AK300652AB
<4G1>
S
BMWire
Battery Starter
motor
AKX01248
<4G6>
S
B M
Battery
Starter
motorWire
AF
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STARTING SYSTEM
ENGINE ELECTRICAL16-28
2. Measure the diameter of the commutator.
Standard value: 29.4 mm
Limit: 28.8 mm
3. Measure the depth of the undercut between
segments.
Standard value: 0.5 mm
Limit: 0.2 mm
BRUSH HOLDER
Push the brush into the brush holder to make sure
that the spring is working on the brush.
If the spring is not working, replace the brush holder.
OVERRUNNING CLUTCH
1. Make sure that the pinion cannot be turned
counterclockwise and can be turned clockwise
freely.
2. Check the pinion for abnormal ware and damage.
BRUSHES
1. Check the commutator contacting surface of each
brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
contact surface with sandpaper wrapped around
the commutator.
ARMATURE COIL
1. Check the armature coil for short circuit as
follows:
AK202715
AK202711
SegmentUndercut
Mica
AB
AK201187
AK202710
Free
Lock
AB
AK202846
Brush
height
AB
