Disassembly and Reassembly
COMPONENTS FOR DISASSEMBLY AND ASSEMBLY
STARTER 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 N.m (60 kgf.cm, 52 in.lbf)
(b) Remove the 2 through bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
(c) Pull out the field frame together with the armature.
ASSEMBLY HINT: Align the protrusion of the field frame with the groove of the magnetic switch.
(d) Remove the O-ring from the field frame.
ASSEMBLY HINT: Use a new O-ring.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
(a) Remove the 2 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
(b) Remove these parts from the magnetic switch:
(1) Starter housing
(2) Return spring
(3) Idler gear
(4) Bearing a
(5) Clutch assembly
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, 2 O-rings and end cover from the field frame.
ASSEMBLY HINT: Use 2 new O-rings.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
(b) Remove the O-ring from the field frame.
ASSEMBLY HINT: 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.
ASSEMBLY NOTE: Check that the positive (+) lead wires are not grounded.
6. REMOVE ARMATURE FROM FIELD FRAME.
MAGNETIC SWITCH TERMINAL KIT
PARTS REPLACEMENT
1. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
2. INSPECT CONTACT PLATE FOR WEAR
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.
3. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810-38140
(b) Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
(c) Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.
4. REINSTALL TERMINAL KIT PARTS
(a) Install these new parts:
Terminal 30:
(1) Insulation paper
(2) Terminal insulator (inside)
NOTE: Be careful to install the terminal insulator in the correct direction.
(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
Terminal C:
(1) Terminal insulator (inside)
NOTE: Be careful to Install the terminal insulator in the correct direction.
(2) Contact plate
(3) Terminal bolt
(4) O-ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
(b) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) 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 kgf, 221 lbf)
NOTE:
^ Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) 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.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (170 kgf.cm, 12 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.
Torque: 2.5 N.m (26 kgf.cm, 23 in.lbf)
STARTER ASSEMBLY
Assembly is in the reverse order of disassembly.