Starter Drive Gear: Service and Repair

Disassembling and Assembling Transmission Gear


NOTE: Starting motor removed





- Unscrew heat-protection plate (if installed).
- Unscrew bracket.
- Check spacers.




- Remove solenoid switch.
- Unscrew both studs.

Installation:
- Clean all parts thoroughly before assembling.




- Separate motor (1) and transmission (2).

Installation:
- Groove (3) should be aligned with rubber part (4).




- Take off protective cap.
- Remove retainer (1) and shims (2).

Installation:
- Check axial clearance, correcting if necessary.




- Check armature shaft, removing burrs if necessary.
- Take off cover.




- Insert a 22 mm wrench socket or piece of pipe (with an outside diameter of approx. 30 mm) in order to prevent the carbon brushes from springing out.






Installation:
- Use wrench socket or pipe again to make installation easier.
- Mount entire assembly on transmission case and then tighten cable socket.




- Take off cover and rubber block.




- Pull out transmission unit.
- Take toothed ring off planetary transmission and release.
1. Planetary transmission
2. Release
3. Pinion
4. Transmission case






Installation:
- Openings and bores must be aligned.




- Check bearing and, if necessary, drive it out with a suitable mandrel.

Installation:
- Lubricate new bearing with grease and press it in.
- A = approx. 1 mm.




- Turn drive pinion against stop. Pinion will be very easy to turn if one-way clutch is worn.
- Check bearing sleeve and teeth of pinion for wear.




- Knock back thrust ring (1). Pull off retainer (2) in forward direction.
- If applicable, remove burrs and take off drive pinion.

Installation:
- Clean bearing surface of pinion thoroughly and lubricate with grease.




- Pull off Circlip (1) and take off washers.
1. Circlip
2. Metal washer
3. Plastic washer





- Take off bearing cover (4) and washers (5).
- Check bearing sleeve (6), replacing if necessary.

Installation:
- Lubricate sleeve with oil after pressing it in.




- Checking bearing sleeve and, if necessary, remove it with a suitable puller.
- Check planet gears for wear.
Installation:
- Lubricate sleeve with oil after pressing it in.