STARTER MOTOR ASSEMBLY INSPECTION <4N1>


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.
3.
caution This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning out.
Set the switch to "ON", and pinion will move out.

4.Push the pinion back with a finger and measure the pinion stroke (the travel along which the pinion is pushed back).
This is the pinion gap.
Standard value: 0.5 - 2.0 mm

5.If the pinion gap is not up to specification, adjust by adding or removing fibre washers between the magnetic switch and the front bracket. Using more washers makes the gap smaller.

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.

MAGNETIC SWITCH HOLD-IN TEST

1.Disconnect the field coil wire from the M-terminal of the magnetic switch.
2.
caution This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
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 (150-ampere scale or more) and carbon pile rheostat in series between the positive 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 negative battery terminal to the starter motor body.
6.Adjust the rheostat until the battery positive 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:

    maximum 120 A <Vehicles without AS&G system>
    maximum 140 A <Vehicles with AS&G system>

MAGNETIC SWITCH RETURN TEST

1.Disconnect the field coil wire from the M-terminal of the magnetic switch.
2.
caution This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
Connect a 12-volt battery between the M-terminal and body.
3.
warning Be careful not to get your fingers caught when pulling out the pinion.
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.