TOHATSU 40 Service Manual page 269

SECTION 7
Starter Motor Tests
• If the engine does not crank and you completed the Starter
Circuit Tests previously described, remove the starter motor and
inspect the brush assembly. If the brush assembly meets
specifications, replace the starter motor or have it rebuilt.
• If the starter motor runs but the starter motor does not engage or
disengage from the flywheel, remove the starter motor and
inspect the pinion assembly. If the pinion assembly meets
specifications, inspect the flywheel for chipped or worn teeth
and replace as needed.
Remove Starter Motor
Disconnect negative battery cable from battery
before removing starter motor.
For models 40 / 50 / 80 / 90 / 115 / 120 / 140 move
oil tank out of the way for access.
1. Disconnect starter solenoid cable (1) and ground cable
17
(2).
2. Remove starter motor band bolts and starter motor band
17
(3).
3. Remove mounting bolts and slide starter motor out of
17
bracket (4).
4. Clean bracket with cleaning solvent.
Inspect and Remove Pinion Assembly
1. Grasp pinion collar (1) and wind pinion gear (2) in a
18
clockwise direction (view from top). Make sure gear moves
freely and returns to original position. If any binding is noted,
remove and replace pinion assembly.
7-90
NOTE
T1516
T1524
3-/ 4-Cylinder