Overhaul

STARTER

DISASSEMBLY
1. Disconnect M terminal (A) from magnet switch assembly.







2. Remove the magnet switch assembly from the starter housing assembly.







3. Remove through bolts (A) on both sides and the brush holder screws (B), and remove the starter cover assembly.







4. Remove the yoke assembly and brush holder assembly as a unit.







5. Remove the two brushes wired to the yoke assembly, and separate the yoke assembly and the brush holder assembly.

NOTE: As shown in the figure, use a flat tip screwdriver, etc. to hold the brush spring and remove the brush.







6. Remove the armature from the internal gear assembly.







7. Remove the starter housing assembly (A) then remove the shift lever (B).







8. Use the following procedures to remove the overrunning clutch from the shaft.
1. Use an appropriate tool (such as a fit socket wrench), and remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer.







2. Remove snap ring (A) from the shaft, and remove stopper (B).







3. Remove the overrunning clutch from the shaft.







9. Use the following procedures to remove the shaft.
1. Remove the starter plate, and remove the pinion gear.







2. Remove the snap ring from the shaft.







3. Remove the shaft from the internal gear assembly.







ASSEMBLY
1. Use the following procedures to install the shaft.
1. Apply grease to the sliding surfaces of the internal gear assembly shaft.
Grease: DENSO HL50

2. Assemble the shaft to the internal gear assembly.







3. Install the snap ring to shaft.

NOTE: Use new snap rings.







4. Apply grease to the pinion gear attachment area.
Grease: DENSO HL50

5. Attach the pinion gear to the pin.
6. Apply grease to the pinion gear, internal gear assembly, and on top of the shaft pin.

NOTE:
- Apply grease so that it contacts each gear.
- Be careful not to allow dirt to get in.







7. Install the starter plate.

2. Assemble the overrunning clutch and shift lever (B) to the starter housing (A) as a unit.

NOTE: Apply grease to the contact portion of the shift lever.







3. Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.
Grease: DENSO HL50

2. Install the overrunning clutch to shaft.







3. Pass stopper (B) through the shaft, and attach snap ring (A).

NOTE: Use new snap rings.







4. Using a press, pressure fit stopper (B) into snap ring (A).







4. Install the armature to the internal gear assembly.







5. Attach the two brushes wired to the yoke assembly to the brush holder assembly.

NOTE: As shown in the figure, use a flat tip screwdriver, etc. to hold the brush spring and insert the brush while being careful not to damage the brush.







6. Install the yoke assembly and brush holder assembly as a single unit to the armature.

NOTE: Spread the brush with your fingers, being careful not to damage the brush.







7. Install starter cover assembly to the brush holder assembly with screws (B).

Tightening torque: 1.4 N.m (0.1 kgf-m, 1.0 ft-lb)

8. Tighten the through bolts (A) on both sides.







9. Attach the magnet switch assembly to the starter housing assembly.







10. Connect M terminal (A) to magnet switch assembly.