Remove the starter. Refer to Starter Motor Replacement .

Perform Pinion Clearance

Notice: Refer to Engine Emission Notice in the Preface section.




1. Disconnect the starter motor terminal M (2).
2. Connect the 12-volt battery lead to the starter motor terminals M and S.
3. Switch ON to move the pinion gear (1).



4. Check the clearance between the pinion and the stopper with the filler gage (a).
5. If the clearance does not fall within the limits, check for improper installation and replace all worn parts.

Magnetic Switch Pull-in Test

Notice: Refer to Engine Emission Notice in the Preface section.




1. Disconnect the starter motor terminal M (1).
2. Connect the 12-volt battery lead to the starter motor terminals M and S.



3. Check that the pinion gear is moving to the outside (1).
4. If the pinion gear does not move outside, replace the magnetic switch.

Solenoid Hold-in Test

Notice: Refer to Engine Emission Notice in the Preface section.




1. Disconnect the starter motor terminal M (1).
2. Connect the 12-volt battery lead to the starter motor terminal S and body.



3. Check that the pinion gear is moving to the outside (1).
4. If the pinion gear moves to the inside, the circuit is open. Replace the magnetic switch.

Solenoid Return Test

Notice: Refer to Engine Emission Notice in the Preface section.




1. Disconnect the starter motor terminal M (1).
2. Connect the 12-volt battery lead to the starter motor terminal S and body.



3. Check the returning speed of pinion gear (1). If the returning speed is fast, the operation is normal.
4. Replace the solenoid if the operation is abnormal.

No-Road Test

1. Connect the 12-volt battery lead to the starter circuit.
2. Connect the current and the voltage (1).
3. Install the starter motor RPM gage.
4. Start the starter motor with the switch on (2).
5. Measure the speed of pinion gear and the current.
6. If the measurements satisfy the limit, the starter motor is normal.



7. Replace the starter motor, if necessary.

Specification
The minimum pinion gear (1) speed is 2,000 RPM.

Specification
The maximum starter motor voltage/current is 9 V/150 AMP.