Disassembly and Reassembly
DISASSEMBLY1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)
b. Remove the 2 through bolts.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)
c. Pull out the field frame together with the armature.
HINT: Align the protrusion of the field frame with the groove of the magnetic switch.
d. Remove the O-ring from the field frame.
HINT: At the time of installation, please refer to the following items. Use a new O-ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
a. Remove the 2 screws.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)
b. Remove these parts from the magnetic switch:
1. Starter housing and clutch assembly
2. Return spring
3. Idler gear
4. Bearing
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
5. REMOVE BRUSH HOLDER
a. Remove the 2 screws and end cover from the field frame.
Torque: 1.5 Nm (15 kg.cm, 13 in.lb)
b. Remove the O-ring from the field frame.
HINT: At the time of installation, please refer to the following items. Use a new O-ring.
c. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
NOTE: Check that the positive (+) lead wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT: Use high-temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the starter.
REPLACEMENT
1. REPLACE CLUTCH ASSEMBLY
a. Disassemble the starter housing and the clutch assembly.
1. Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar.
2. Push down the pinion gear.
3. Using a plastic-faced hammer, tap down the stop collar.
4. Using a screwdriver, pry out the snap ring.
5. Remove these parts:
- Stop collar
- Pinion gear
- Compression spring
6. Push down the starter housing, and remove the spring retainer.
7. Disassemble these parts:
- Starter housing
- Starter clutch
- Compression spring
- Clutch shaft
b. Assemble the starter housing and the clutch assembly
1. Assemble these parts:
- Starter housing
- Starter clutch
- Compression spring
- Clutch shaft
2. Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar.
3. Push down the starter housing, and install these parts:
- Spring retainer
- Compression spring
- Pinion gear
- Stop collar
4. Push down the pinion gear.
5. Using snap ring pliers, install a new snap ring.
6. Using pliers, compress the snap ring.
7. Check that the snap ring fits correctly.
8. Remove the starter housing and clutch assembly from the brass bar.
9. Using a plastic-faced hammer, tap the clutch shaft and install the stop collar onto the snap ring.
2. REPLACE FRONT BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
NOTE: Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
4. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove the 3 bolts, end cover, gasket and the plunger.
b. Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove the terminal kit parts.
1. Using SST loosen the terminal nuts.
SST 09810-38140
2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.
d. Temporarily install these new terminal 30 kit parts:
1. Insulation paper
2. Terminal insulator (inside)
3. Contact plate
4. Terminal bolt
5. O-ring
6. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
7. Wave washer
8. Terminal nut
NOTE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction.
e. Temporarily install these new terminal C kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Terminal insulator (outside)
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force: 981 N (100 kg, 221 lb)
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied.
Gauge pressure
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 Nm (173 kg.cm, 13 ft.lb)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall the plunger, new gasket and end cover with the 3 bolts.
Torque: 2.5 Nm (26 kg.cm, 23 in.lb)