Overhaul
STARTERDISASSEMBLY
1. REMOVE REPAIR SERVICE STARTER KIT
a. Remove the nut, and disconnect the lead wire from terminal C.
b. Remove the 2 screws and repair service starter kit from the starter drive housing.
c. Remove the return spring and the plunger from the repair service starter kit.
2. REMOVE STARTER YOKE ASSEMBLY
a. Remove the 2 bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly from the starter drive housing assembly.
b. Remove the starter yoke from the starter commutator end frame.
3. REMOVE STARTER ARMATURE PLATE
a. Remove the starter armature plate from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME COVER
a. Using a screwdriver, remove the starter commutator end frame cover from the starter commutator end frame.
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.
c. Remove the starter armature assembly and plate washer from the commutator end frame.
NOTE: Do not drop the starter armature assembly.
6. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears from the starter drive housing.
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Remove the starter center bearing clutch sub-assembly with the starter drive lever set pin from the starter drive housing.
b. Remove the starter drive lever set pin from the starter center bearing clutch sub-assembly.
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 to the starter center bearing clutch sub-assembly.
c. Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.
2. INSTALL PLANETARY GEAR
a. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.
b. Install the 3 planetary gears.
3. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply high-temperature grease to the plate washer, new snap ring and bearing, as shown in the illustration.
b. Install the armature assembly to the starter commutator end frame assembly.
c. Install the plate washer to the armature shaft.
d. Using snap ring pliers, install the 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.
e. Using vernier calipers, measure the snap ring.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than the maximum, replace the snap ring.
4. INSTALL STARTER COMMUTATOR END FRAME COVER
a. Install the starter commutator end frame cover to the starter commutator end frame assembly.
5. INSTALL STARTER ARMATURE PLATE
a. Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the starter commutator end frame rubber with the groove of the starter yoke assembly.
b. Install the starter commutator end frame to the starter yoke assembly.
NOTE: The magnet of the starter yoke assembly may attract the starter armature when the starter commutator end frame assembly is installed, causing magnet breakage.
7. INSTALL STARTER YOKE ASSEMBLY
a. Align the claw of the starter yoke assembly with the groove inside the starter drive housing.
b. Install the starter yoke assembly with the 2 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 the return spring.
d. Install the repair service starter kit with the 2 screws.
Torque: 7.5 N.m (77 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)