#
STARTER INSPECTION [MZR-CD (RF Turbo)]

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## On-vehicle Inspection

1. Verify that the battery is fully charged.

2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.

  • If the starter does not operate, inspect the following:

  - Remove the starter, and inspect the starter unit.
  - Inspect the related wiring harnesses and the engine switch.

## No-load test

1. Verify that the battery is fully charged.

2. Connect the starter, battery, and a tester as shown in the figure.

3. Operate the starter and verify that it rotates smoothly.

  • If the starter does not rotate smoothly, inspect the starter unit.

4. Measure the voltage and current while the starter is operating.

  • If not within the specification, replace the starter.

Starter no load test voltage

  11 V

Starter no load test current

  130 A or less

## Magnetic Switch Operation Inspection

### Pull-out test

  Note

  • Depending on the battery charge condition, the starter motor pinion may rotate while in a protracted state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.

1. Verify that the starter motor pinion is protracted while battery positive voltage is connected to terminal S and the starter body is grounded.

  • If not pulled out, repair or replace the starter.

### Return test

1. Disconnect the motor wire from terminal M.

2. Connect battery positive voltage to terminal M and ground the starter body.

3. Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.

  • If it does not return, repair or replace the starter.

## Pinion Gap Inspection

1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded.

  Caution

  • Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s.

2. Measure the pinion gap while the drive pinion is pulled.

  • If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch).

Starter pinion gap

  0 mm {0 in}

## Starter Inner Parts Inspection

### Armature

1. Verify that there is no continuity between the commutator and the core at each segment using a tester.

  • If there is continuity, replace the armature.

2. Verify that there is no continuity between the commutator and the shaft using a tester.

  • If there is continuity, replace the armature.

3. Place the armature on V-blocks, and measure the runout using a dial indicator.

Starter armature runout

  0.1 mm {0.039 in} max.

4. Measure the commutator diameter.

  • If not within the minimum specification, replace the armature.

Starter commutator diameter

  Standard: 32 mm {1.26 in}
  Minimum: 31.4 mm {1.24 in}

5. Measure the segment groove depth of the commutator.

  • If not within the minimum specification, undercut the grooves to the standard depth.

Segment groove depth of starter commutator

  Standard: 0.4-0.6 mm {0.016-0.023 in}
  Minimum: 0.2 mm {0.008 in}

### Magnetic switch

1. Inspect for continuity between terminals S and M using a tester.

  • If there is no continuity, replace the magnetic switch.

2. Inspect for continuity between terminal S and the body using a tester.

  • If there is no continuity, replace the magnetic switch.

3. Verify that there is no continuity between terminals M and B using a tester.

  • If there is continuity, replace the magnetic switch.

### Brush and brush holder

1. Verify that there is no continuity between each insulated brush and plate using a tester.

  • If there is continuity, replace the brush holder.

2. Measure the brush length.

  • If any brush is worn almost to or beyond the minimum specification, replace all the brushes.

Starter brush length

  Standard: 17.5 mm {0.69 in}
  Minimum: 11 mm {0.43 in}

3. Measure the brush spring force using a spring balance.

  • If not within the minimum specification, replace the brush spring.

Starter brush spring force

  Standard: 26.7-36.1 N {2.73-3.68 kgf, 6.01-8.11 lbf}
  Minimum: 14.7 N {1.5 kgf, 3.3 lbf}