Overhaul
DISASSEMBLY1. REMOVE STARTER MAGNETIC SWITCH ASSEMBLY
a. Remove the nut, and disconnect the lead wire from the magnetic switch.
b. Remove the 2 nuts and starter magnetic switch assembly.
2. REMOVE STARTER DRIVE HOUSING ASSEMBLY
a. Using a T30 "TORX" socket wrench, remove the 2 bolts.
b. Pull out the starter yoke assembly and the starter commutator end frame assembly together with the armature.
3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY
a. Remove the starter pinion drive lever.
b. Remove the 2 screws and end frame.
NOTE: While holding down the lead wire, remove the start commutator end frame.
4. REMOVE STARTER ARMATURE 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.
c. Remove the starter armature from the yoke.
5. REMOVE STARTER YOKE ASSEMBLY
a. Remove the starter yoke from the starter center bearing clutch sub-assembly.
6. REMOVE STARTER ARMATURE PLATE
a. Remove the armature plate from the center bearing clutch sub-assembly.
7. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears.
REASSEMBLY
1. 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.
2. INSTALL STARTER ARMATURE PLATE
a. Insert the plate to the center bearing clutch.
NOTE: Check that the tab of the starter armature plate fits over the projection of the starter center bearing clutch sub-assembly.
3. INSTALL STARTER ARMATURE ASSEMBLY
a. Install the starter armature to the starter center bearing clutch sub-assembly.
4. INSTALL STARTER YOKE ASSEMBLY
a. Align the claw of the center bearing clutch with the groove of the starter yoke, and install the starter yoke.
5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Install the starter brush holder assembly.
b. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder.
c. Connect the 4 brushes.
d. Align the starter commutator end frame rubber with the groove of the starter yoke.
e. Install the starter commutator end frame with the 2 screws.
Torque: 3.8 N.m (39 kgf.cm, 33 in.lbf)
6. INSTALL STARTER DRIVE HOUSING ASSEMBLY
a. Apply high-temperature grease to the starter pinion drive lever, as shown in the illustration.
b. Install the pinion drive lever to the center bearing clutch.
c. Align the claw of the starter yoke with the groove inside the drive housing.
d. Using a T30 "TORX" socket wrench, install the drive housing with the 2 bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
7. INSTALL STARTER MAGNETIC SWITCH ASSEMBLY
a. Temporarily install the magnetic switch by hooking its tip to the upper side of the pinion drive lever.
b. Install the 2 nuts.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
c. Connect the lead wire to the terminal with the nut.
Torque: 6.5 N.m (66 kgf.cm, 57 in.lbf)