Overhaul

DISASSEMBLY

HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

1. REMOVE STARTER YOKE ASSEMBLY
a. Disconnect the terminal rubber cap.




b. Remove the nut, and disconnect the lead wire from the magnetic starter switch terminal.
c. Remove the 2 bolts, and pull out the starter yoke with armature from the magnet starter switch.
d. Remove the O-ring from the starter yoke.




2. REMOVE MAGNET STARTER SWITCH ASSEMBLY
a. Remove the 2 screws, and separate the magnet starter switch and starter housing.
b. Remove the O-ring, starter clutch, return spring, idler gear and bearing.
c. Using a magnetic finger, remove the steel ball from the starter clutch shaft hole.




3. REMOVE END COVER
a. Remove the 2 screws and end cover.
b. Remove the dust protector form the end cover.
c. Remove the O-ring from the starter yoke.




4. REMOVE STARTER BRUSH HOLDER ASSEMBLY
a. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder.
b. Disconnect the 4 brushes, and remove the brush holder.

5. REMOVE STARTER ARMATURE ASSEMBLY

REASSEMBLY

1. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the armature bearing.
b. Install the armature into the yoke.

2. INSTALL STARTER BRUSH HOLDER ASSEMBLY
a. Install a new O-ring to the groove of the starter yoke.




b. Place the brush holder on the starter yoke.
c. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder.
d. Connect all 4 brushes.

NOTE: Check that the positive lead wires are not grounded.

e. Install the dust protector to the end cover.




f. Install the end cover to the starter yoke with the 2 screws.

Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)

3. INSTALL MAGNET STARTER SWITCH ASSEMBLY




a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.




c. Apply grease to the return spring.
d. Apply grease to the steel ball and return spring, and then insert the return spring into the magnet starter switch hole.
e. Apply grease to the idler gear, retainer and clutch roller.




f. Place a new O-ring (1), the starter clutch (2), idler gear (3), retainer (4) and clutch roller (5) on the starter housing.




g. Install the starter housing to the magnet starter switch with the 2 screws.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

4. INSTALL STARTER YOKE ASSEMBLY




a. Install a new O-ring to the groove of the starter yoke.
b. Align the protrusion of the starter yoke with the groove of the magnet starter switch.




c. Install the starter yoke and armature with the 2 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)

e. Connect the terminal rubber cap to the terminal C.