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 kgf.cm, 52 in.lbf)
b. Remove the 2 through bolts.
Torque: 9.3 Nm (95 kgf.cm, 82 in.lbf)
c. Pull out the field frame together with the armature.
NOTE: At the time of notice, please refer to the following items. 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 assembly, 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: 9.3 Nm (95 kgf.cm, 82 in.lbf)
b. Remove these parts from the magnetic switch:
1. Starter housing
2. Return spring
3. Idler gear
4. Bearing
5. Starter clutch assembly
HINT: At the time of assembly, please refer to the following items.
Apply grease to the return spring and insert the return spring into the clutch shaft hole.
4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
HINT: At the time of assembly, please refer to the following items.
Apply grease to the steel ball and insert the steel ball into the clutch shaft hole.
5. REMOVE BRUSH HOLDER
a. Remove the 2 screws, and end cover from the field frame.
Torque: 3.8 Nm (39 kgf.cm, 34 in.lbf)
b. Remove the O-ring from the field frame.
HINT: At the time of assembly, 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: At the time of assembly, please refer to the following items.
Use high-temperature grease to lubricate the bearing and gears when assembling the starter.
REPLACEMENT
1. REPLACE REAR BEARING
a. Using SST remove the bearing.
SST 09286 - 46011
b. Using a press, press in a new bearing.
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 MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover.
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
b. 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.
c. Remove 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), 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 nut.
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 Nm (170 kgf.cm, 13 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.
Torque: 3.6 Nm (37 kgf.cm, 32 in.lbf)