Overhaul

Starter Assy:

OVERHAUL

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 to the starter housing.
c. Remove the repair service starter kit.
d. Remove the return spring and plunger.

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

3. REMOVE STARTER ARMATURE ASSEMBLY




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




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

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




5. REMOVE PLANET GEAR
a. Remove the 3 planet gears.




6. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Remove the starter center bearing clutch w/ drive lever set pin from the starter drive housing.
b. Remove the drive lever set pin from the starter center bearing clutch.

7. INSPECT STARTER ARMATURE ASSEMBLY




a. Inspect the commutator for open circuit.
1. Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segments, replace the armature.




b. Inspect the commutator for ground.
1. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.

c. Inspect the commutator surface for dirt or burnout.
If the surface is dirty or burnt, correct it with 400-grit sandpaper or a lathe.




d. Using vernier calipers, measure the commutator length.
Standard length: 3.1 mm (0.122 in.)
Maximum length: 3.8 mm (0.150 in.)
If the length is greater than maximum, replace the armature.

8. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY




a. Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Maximum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter assembly.




b. Inspect the brush holder.
1. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brushes.
If the there is continuity, repair or replace the starter assembly.

9. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Inspect the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
If the gear is damaged, replace it.
If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage.




b. Inspect the starter clutch.
1. Rotate the clutch pinion gear clockwise and check that it turns freely. Try to rotate the clutch pinion gear counterclockwise and check that it locks.
If necessary, replace the center bearing clutch sub-assembly.

10. INSPECT REPAIR SERVICE STARTER KIT




a. Inspect the plunger.
1. Push in the plunger and check that it returns quickly to its original position.
If necessary, replace the starter assembly.




b. Inspect the pull-in coil for open circuit.
1. Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, replace the starter assembly.




c. Check if the holding coil has an open circuit.
1. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, replace the starter assembly.




11. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Install the drive lever set pin to the starter center bearing clutch.
b. Install the starter center bearing clutch w/ drive lever set pin to the starter drive housing.




12. INSTALL PLANET GEAR
a. Apply grease to the planet gears and pin parts of the planetary shaft.
b. Install the 3 planet gears.




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

14. INSTALL STARTER ARMATURE ASSEMBLY




a. Apply grease to the washer plate and armature shaft.
b. Install the armature shaft to the starter commutator end frame assembly.
c. Using snap ring pliers, install the plate washer and snap ring.




d. Using vernier calipers, measure the snap ring length.

Maximum length: 5.0 mm (0.197 in.)

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

15. INSTALL STARTER COMMUTATOR END FRAME COVER




16. INSTALL STARTER YOKE ASSEMBLY
a. Align the starter commutator rubber end frame with the cutout of the starter yoke.
b. Install the starter yoke assembly to the starter commutator end frame.

17. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY




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




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

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

18. INSTALL REPAIR SERVICE STARTER KIT




a. Apply grease to the plunger and hook.
b. Put the plunger hook of the repair service starter kit on the drive lever.
c. Install the plunger and return spring.
d. Install the repair service starter kit with the 2 screws.

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




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

Torque: 10 Nm (102 kgf.cm, 7.4 ft.lbf)