Test
1. SWITCH ASSEMBLY OPERATION1. Connect terminal S of switch assembly to positive terminal of battery with a lead wire and starter body to ground terminal of battery. Pinion should be forced end-wise on shaft.
CAUTION: With pinion forced endwise on shaft, starter motor can sometimes rotate because current flows, through pull-in coil, to motor. This is not a problem.
2. Disconnect connector from terminal M, and connect positive terminal of battery and terminal M using a lead wire and ground terminal to starter body.
In this test set up, pinion should return to its original position even when it is pulled out with a screwdriver.
2. PINION GAP
1. With pinion forced endwise on shaft, as outlined in step 1 above, measure pinion gap.
Pinion gap:
0.5 - 2.0 mm (0.020 - 0.079 in)
If motor is running with the pinion forced endwise on the shaft, disconnect connector from terminal M of switch assembly and connect terminal M to ground terminal (-) of battery with a lead wire. Next, gently push pinion back with your fingertips and measure pinion gap.
2. If pinion gap is outside specified range, remove or add number of adjustment washers used on the mounting surface of switch assembly until correct pinion gap is obtained.
3. PERFORMANCE TEST
The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine.
Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test.
For these performance tests, use the circuit shown in figure.
1. No-load test
With switch on, adjust the variable resistance to obtain 11 V, take the ammeter reading and measure the starter speed. Compare these values with the specifications.
No-load test (Standard):
Voltage / Current: 11 V / 90 A or less
Rotating speed: 3,000 rpm or more
2. Load test
Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within specifications.
Load test (Standard):
MT vehicles
Voltage / Load: 8 V / 8.5 N.m (0.87 kg-m, 6.27 ft-lb)
Current / Speed: 280 A / 980 rpm or more
AT vehicles
Voltage / Load: 7.7 V / 9.81 N.m (1.00 kg-m, 7.24 ft-lb)
Current / Speed: 300 A max. / 1,000 rpm or more
3. Lock test
With starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to the specified voltage.
Lock test (Standard):
MT vehicles
Voltage / Load: 4 V / 780 A or less
Torque: 17.6 N.m (1.80 kg-m, 13.0 ft-lb) or more
AT vehicles
Voltage / Current: 4 V / 980 A or less
Torque: 23 N.m (2.3 kg-m, 17 ft-lb) or more