Overhaul

DISASSEMBLY

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

1. REMOVE STARTER YOKE ASSEMBLY




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

2. REMOVE MAGNET STARTER SWITCH ASSEMBLY




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

3. REMOVE END COVER




a. Remove the 2 screws and end cover.

4. REMOVE STARTER BRUSH HOLDER ASSEMBLY




a. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. 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 bearings.
b. Insert the armature into the yoke.

2. INSTALL STARTER BRUSH HOLDER ASSEMBLY




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

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

c. Install a new O-ring to the groove of the starter yoke.




d. 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. Insert the return spring into the magnetic switch hole.




e. Place a new O-ring (1), the starter clutch (2), idler gear (3), and bearing (4), on the starter using.




f. Install the starter housing to the magnetic 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 magnetic switch, and install the starter yoke and armature.




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. Install a new dust protector.