Overhaul

DISASSEMBLY

1. REMOVE STARTER MAGNETIC SWITCH ASSEMBLY




a. Remove the nut and disconnect the lead wire.




b. Remove the 2 screws and starter magnetic switch.




c. Remove the return spring and plunger from the starter drive housing.

2. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY




a. Remove the 2 bolts and the starter commutator end frame together with the starter yoke.




b. Remove the starter commutator end frame from the starter yoke.




c. Remove the starter armature plate from the starter yoke.

3. REMOVE STARTER ARMATURE ASSEMBLY




a. Using a thin-bladed screwdriver, remove the starter commutator end frame cover.




b. Using snap ring pliers, remove the snap ring.




c. Remove the plate washer and starter armature from the starter commutator end frame.

4. REMOVE STARTER PLANETARY GEAR




a. Remove the 3 planetary gears from the starter drive housing.

REASSEMBLY

1. INSTALL STARTER PLANETARY GEAR




a. Apply grease to the planetary gears and pins parts of the planet shaft.




b. Install the 3 planetary gears into the pin of the planet shaft.

2. INSTALL STARTER ARMATURE ASSEMBLY




a. Apply grease to the plate washer, armature shaft and new snap ring.
b. Install the starter armature and plate washer into the starter commutator end frame.




c. Using snap ring pliers, install the snap ring.
d. Check the snap ring length.




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

Maximum length: 5.0 mm (0.197 in.)

If the snap ring length is greater than the maximum, replace the snap ring.




e. Install the commutator end frame cover into the starter commutator end frame.

3. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY




a. Align the rubber of the starter commutator end frame with the convex cutout of the starter yoke, and then install the starter commutator end frame into the starter yoke.




b. Align the keyway of the starter armature plate with the key inside the starter yoke, and then install the starter armature plate into the starter yoke.




c. Apply grease to the starter armature gear.




d. Align the key of the starter yoke with the keyway of the starter drive housing, and then install the starter commutator end frame together with the starter yoke into the starter drive housing.
e. Install the 2 bolts.

Torque: 6.0 N.m (60 kgf.cm, 53 in.lbf)

4. INSTALL STARTER MAGNETIC SWITCH ASSEMBLY




a. Apply grease to the plunger and hook.




b. Install the plunger and return spring into the starter drive housing.




c. Install the starter magnetic switch into the starter drive housing.
d. Install the 2 screws.

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




e. Connect the lead wire with the nut.

Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)