Disassembling/Assembling Starter
- Remove solenoid.
- Unscrew dust cap (2).
- Takeoff retainer (3), shims (4) and seal (5).
Installation Note:
- Check axial play of armature, correcting with shims if necessary.
- Unscrew housing bolts and take off cover.
Installation Note:
- Align openings for housing bolts and insulator to each other.
- Check bearing sleeve, lubricating with oil before installing.
- Lift springs and pull out carbon brushes.
- Remove holder.
Installation Note:
- Check carbon brushes and commutator for wear, repairing if necessary.
- Remove pole housing.
- Unscrew engaging lever bolt and remove rubber seal.
- Lift out armature with drive pinion and engaging fork.
Installation Note:
- Lubricate guide for engaging fork with grease.
- Check bearing sleeve in drive bearing bracket, lubricating with oil prior to installation.
- Push beck bearing race (1) with a piece of suitable pipe.
- Pry circlip (2) apart and pull it off of the shaft.
- Remove burrs with a file.
- Take off drive pinion (3).
Installation Note:
- Use a new circlip (2).
- Lubricate bearing surface for drive pinion with grease.
Installation Note:
- Check pinion for wear (on teeth, bearings, one-way clutch), replacing if necessary.
- Check sleeve in intermediate bearing, replacing if necessary.
REPLACING CARBON BRUSHES
- Lift springs and pull out carbon brushes
- Take off holder and pole housing.
- Unsolder or cut off all carbon brushes.
- When soldering in new carbon brushes make sure that copper leads are not hardened with flowing solder.
- Check commutator for wear fine grinding if necessary.
- Diameter must be at least 33.5 mm (1.319").
- Machine insulation between plates approx. 0.5 to 0.7 mm (0.020 to 0.027") deep.
REPLACING CARBON BRUSHES - Starter and Layshaft Disassembled
- Fine grind and polish commutator.
- File or machine insulation between commutator plates to depth of 0.5 to 0.7 mm (0.020 to 0.027").
- Check for shorted turns after machining.
- Slide carbon brush holder to center end lift off.
Installation Note:
- Engage hooks of carbon both holder completely.
- Two carbon brushes must be cut off of the leads.
- Solder in new carbon brushes.
DISASSEMBLY AND ASSEMBLY OF THE LAYSHAFT
- Unscrew heat shield (if applicable).
- Unscrew bracket.
- Check spacers.
- Remove solenoid.
- Unscrew both studs.
Installation Note:
- Clean all components thoroughly prior to assembling.
- Separate motor (1) and gearbox (2).
Installation Note:
- Groove (3) must be aligned wish rubber part (4).
- Takeoff cap.
- Takeoff retainer (1) and shims (2).
Installation Note:
- Check axial play, correcting if necessary.
- Inspect armature shaft, removing burrs if necessary.
- Take off cover.
- Prevent the carbon brushes from popping out by inserting a 22 mm wrench socket or a pipe with an outside diameter of approx. 30 mm (1.181").
Installation Note:
- Use wrench socket or pipe again to make installation easier.
- Mount entire unit on the gearbox case and then tighten the wire connector.
- Take off cover and rubber pad.
1 Planet gearbox
2 Release
3 Pinion
4 Gearbox case
- Pull Out gearbox unit.
- Take off toothed ring on planet gearbox and release.
Installation Note:
- Openings and bores must be aligned.
- Check bearing. driving it out with a suitable mandrel if necessary.
Installation Note:
- Lubricate new bearing with grease and press in.
- Distance A = approx. 1 mm (0.039").
- Turn drive pinion against stop.
- Pinion will be very easy to turn, if the one-way clutch is worn.
- Check bearing sleeve and teeth of pinion for wear.
- Knock back thrust ring (1).
- Pull off retainer (2) forward.
- Remove burrs if applicable.
- Then take off drive pinion.
Installation Note:
- Clean bearing surface for pinion thoroughly and lubricate with grease.
- Pull off retainer (1) and take off washers.
- 2 Metal washer
- 3 Plastic washer
- Take off bearing cover (4) and washers (5).
- Check bearing sleeve (6), replacing it necessary.
Installation Note:
- Lubricate sleeve with oil after pressing in.
- Check bearing sleeve, removing with a suitable puller if necessary.
- Check planet gears for wear.
Installation Note:
- Lubricate sleeve with oil after pressing in.