Disassembly and Reassembly

DISASSEMBLY
1. 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.
d. Remove the O-ring from the field frame.

ASSEMBLY NOTE: Align the protrusion of the field frame with the groove of the magnetic switch.

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.




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.

ASSEMBLY NOTE: Check that the positive (+) lead wires are not grounded.

6. REMOVE ARMATURE FROM FIELD FRAME


Field Frame (Field Coil)




1. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.




2. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between the field coil end and field frame.
If there is continuity, repair or replace the field frame.

Clutch And Gears
1. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or damage.




2. INSPECT CLUTCH PINION GEAR
Hold the starter clutch and rotate the pinion gear counter-clockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.

3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY
A. Disassembly of starter housing and clutch assembly




a. Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar.




b. Push down the pinion gear.
c. Using a plastic-faced hammer, tap down the stop collar.




d. Using a screwdriver, pry out the snap ring.




e. Remove these parts:
1. Stop collar
2. Pinion gear
3. Compression spring




f. Push down the starter housing, and remove the spring retainer.




g. Disassemble these parts:
1. Starter housing
2. Starter clutch
3. Compression spring
4. Clutch shaft

B. Assemble starter housing and clutch assembly




a. Assemble these parts:
1. Starter housing
2. Starter clutch
3. Compression spring
4. Clutch shaft




b. Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar.




c. Push down the starter housing, and install these parts:
1. Spring retainer
2. Compression spring
3. Pinion gear
4. Stop collar




d. Push down the pinion gear.
e. Using snap ring pliers, install a new snap ring.




f. Using pliers, compress the snap ring.
g. Check that the snap ring fits correctly.




h. Remove the starter housing and clutch assembly from the brass bar.
i. Using a plastic-faced hammer, tap the clutch shaft and install the stop collar onto the snap ring.

REASSEMBLY
Reassembly is in the reverse order of disassembly.