Disassembly and Reassembly

STARTER

DISASSEMBLY

1. REMOVE MAGNET SWITCH BODY




a. Remove the nut, and disconnect the lead wire from the magnet starter switch body.




b. Remove the 2 screws holding the magnet starter switch body.
c. Remove the magnet starter switch body.
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 and commutator end frame together.
b. Remove the starter yoke from the commutator end frame.




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

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 with drive lever set pin from the starter drive housing.
b. Remove the drive lever set pin from the starter center bearing clutch.

REASSEMBLY




1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Install the drive lever set pin onto the starter center bearing clutch.
b. Install the starter center bearing clutch with drive lever set pin to the starter drive housing.




2. INSTALL PLANET GEAR
a. Apply grease to the planet gears and planet shaft pins.
b. Install the 3 planet gears.




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

4. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the washer plate and armature shaft.
b. Install the armature shaft onto the starter commutator end frame.




c. Using snap ring pliers, install the plate washer and snap ring.




d. Using a vernier caliper, measure the snap ring length.

Maximum length: 5.0 mm (0.197 in)

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

5. INSTALL STARTER COMMUTATOR END FRAME COVER
6. INSTALL STARTER YOKE ASSEMBLY




a. Align the rubber of the starter commutator end frame with the cutout of the starter yoke.
b. Install the starter yoke onto the starter commutator end frame.




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




d. Install the starter yoke and commutator end frame with the 2 through bolts.

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

7. INSTALL MAGNET STARTER SWITCH BODY
a. Apply grease to the plunger and hook.
b. Put the plunger hook of the magnet switch body on the drive lever.




c. Install the plunger and return spring as shown in the illustration.
d. Install the magnet switch body with the 2 screws.

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




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

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