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.
b. Remove the 2 through bolts.
c. Pull out the field frame together with the armature from the magnetic switch.
d. Remove the O-ring from the field frame.
3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Remove the 2 screws.
b. Remove these parts from the magnetic switch:
- Starter housing
- Return spring
- Idler gear
- Bearing
- Starter clutch assembly
c. Remove the O-ring from the starter housing.
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.
b. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.
6. REMOVE ARMATURE FROM FIELD FRAME
REPLACEMENT
1. REPLACE FRONT BEARING
a. Using SST, remove the bearing.
SST 092820-46011
b. Using SST and a press, press in a new bearing.
SST 09820-00030
NOTE: Be careful of the installation direction.
2. REPLACE REAR BEARING
a. Using SST, remove the bearing. SST O9280-6O11
b. Using a press, press in a new bearing.
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove the 3 bolts, lead clamp, end cover, gasket and 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, O-ring, terminal bolt, contact plate and terminal insulator (inside).
d. Temporarily install these new terminal 30 kit parts;
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. 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.
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer 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 insulator (inside) and wave washer 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 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.
2. Using SST; tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
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, a new gasket, the end cover and lead clamp with the 3 bolts.
Torque: 3.6 N.m (37 kgf.cm, 32 in.lbf)
REASSEMBLY
HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.
1. PLACE ARMATURE INTO FIELD FRAME
a. Apply grease to the armature bearings.
b. Insert in armature into the field frame.
2. INSTALL BRUSH HOLDER
a. Place the brush holder on the field frame.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.
NOTE: Check that the positive (+) lead wires are not grounded.
c. Install a new O-ring to the groove of the field frame.
d. Install the end cover to the field frame with the 2 screws.
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.
4. INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Apply grease to the return spring.
b. Insert the return spring into the magnetic switch hole.
c. Place these parts on the starter housing:
1. New O-ring
2. Starter clutch assembly
3. Idler gear
4. Bearing
d. Install the starter housing to the magnetic switch with 2 screws.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
a. Install a new O-ring to the groove of the filed frame.
b. Align the protrusion of the field frame with the groove of the magnetic switch, and install the field frame and armature shaft assembly.
c. Install the field frame and armature assembly with the 2 through bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
d. Connect the lead wire to terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
6. INSTALL NEW DUST PROTECTOR