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: 9.3 Nm (95 kg.cm, 82 in.lb)




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 kg.cm, 82 in.lb)




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 kg.cm, 34 in.lb)
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.