TOHATSU 40 Service Manual page 273

SECTION 7
Inspect Brush Assembly
1. Clean starter motor terminal and hardware (1) with
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isopropyl alcohol and fine emery cloth and replace brush
assembly if terminal or hardware cannot be restored to original
condition.
2. Check brushes (2) and (3) for chips, fractures,
29 30 31
and wear. If not within specifications, replace
brush assembly:
Engine Models
40 / 50 / 60 / 70
80 / 90 / 115 /
120 / 140
3. Check spring tension. If springs are weak, replace brush assembly.
4. For models 40 / 50 / 60 / 70 - check continuity with analog
multimeter between :
Brush (2) and (3). Replace brush assembly if meter indicates
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continuity.
Brush (3) and the motor base (4). Replace brush assembly if
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meter indicates continuity.
Brush (3) and the starter motor terminal (1). Replace brush
29
assembly if meter does not indicate continuity.
Brush (2) and the motor base (4). Replace brush assembly if
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meter does not indicate continuity.
For models 80 / 90/ 115 / 120 / 140 - check continuity with an
analog multimeter between:
Brush (2) and (4) and between brush (3) and (4). Replace
30
brush assembly if meter indicates continuity.
Brush (2) and the motor base (5) and between brush (3) and
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the motor base (5). Replace brush assembly if meter
indicates continuity.
Brush (2) and the starter motor terminal (1) and between
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brush (3) and the starter motor terminal (1). Replace brush
assembly if meter does not indicate continuity.
Brush (4) to the and the motor base (5). Replace brush
30
assembly if meter does not indicate continuity.
7-94
Original Length (a)
0.49 in [12.5 mm]
0.55 - 0.59 in
[14 - 15mm]
Repair Limit (b)
0.37 in [9.5 mm]
0.47 in [12.0 mm]
T1520
T1521
T1519
3-/ 4-Cylinder