Overhaul

DISASSEMBLY

1. REMOVE REPAIR SERVICE STARTER KIT




a. Remove the nut, and disconnect the lead wire from the repair service starter kit.




b. Remove the 2 screws holding the repair service starter kit.
c. Remove the repair service starter kit.
d. Remove the return spring and plunger.

2. REMOVE STARTER YOKE ASSEMBLY




a. Remove the 2 through bolts, and pull out the starter yoke and commutator end frame together.




b. Remove the starter yoke from the commutator end frame.




3. REMOVE STARTER ARMATURE PLATE
a. Remove the plate from the starter yoke.




4. REMOVE STARTER COMMUTATOR END FRAME COVER
a. Using a screwdriver, remove the cover.

5. REMOVE STARTER ARMATURE ASSEMBLY
a. Hold the starter commutator end frame in a vise between aluminum plates.

NOTE: Do not overtighten the vise.




b. Using snap ring pliers, remove the snap ring and plate washer.
c. Remove the starter armature from the commutator end frame.

NOTE: Do not drop the starter armature assembly.




6. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears.




7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Remove the starter center bearing clutch together with the drive lever set pin from the starter drive housing.
b. Remove the drive lever set pin from the starter center bearing clutch.

REASSEMBLY

1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY




a. Apply high-temperature grease to the drive lever set pin, as shown in the illustration.




b. Install the drive lever set pin onto the starter center bearing clutch.
c. Install the starter center bearing clutch with drive lever set pin to the starter drive housing.




2. INSTALL PLANETARY GEAR
a. Apply grease to the planetary gears and planetary shaft pins.
b. Install the 3 planetary gears.

3. INSTALL STARTER ARMATURE ASSEMBLY




a. Apply grease to the plate washer and armature shaft.
b. Install the armature shaft onto the starter commutator end frame.




c. Using snap ring pliers, install the plate washer and snap ring.

NOTE:
- Be sure to install the snap ring in the armature shaft groove securely.
- Be sure to properly install the snap ring because it easily expands.




d. Using a vernier caliper, measure the snap ring length.

Maximum length: 5.0 mm (0.197 in)

If the length is greater than the maximum, replace the snap ring with a new one.




4. INSTALL STARTER COMMUTATOR END FRAME COVER
a. Install the starter commutator end frame cover to the starter commutator end frame.




5. INSTALL STARTER ARMATURE PLATE
a. Insert the starter armature plate into the starter yoke.
b. Align the cutout of the plate with the inside protrusion of the starter yoke, and install the plate.




6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the rubber of the starter commutator end frame with the cutout of the starter yoke.
b. Install the starter yoke onto the starter commutator end frame.

7. INSTALL STARTER YOKE ASSEMBLY




a. Align the key located on the starter yoke with the keyway of the starter housing.




b. Install the starter yoke with the 2 through bolts.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

8. INSTALL REPAIR SERVICE STARTER KIT




a. Apply high-temperature grease to the plunger and hook, as shown in the illustration.
b. Hang the plunger hook of the repair service starter kit to the drive lever.
c. Install the plunger and return spring.




d. Install the repair service starter kit with the 2 screws.

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)




e. Connect the lead wire to terminal C with the nut.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)