Overhaul

Starter

DISASSEMBLY

1. Remove the nut which holds terminal M (A) of the magnet switch assembly, then disconnect the harness from the terminal.






2. Remove the nuts fastening the magnet switch assembly to the starter housing, then remove the magnet switch assembly.






3. Remove the starter seal.






4. Remove the through bolts on both sides, and remove the starter housing.






5. Remove the shift lever.






6. Remove the overrunning clutch, shock absorber bearing, and shaft from the yoke as a single unit






7. Use the following procedures to remove the overrunning clutch from the shaft assembly.
1. Use an appropriate tool (such as a fit socket wrench), 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.






8. Remove the shock absorber in the following procedures:
1. Remove the starter plate.






2. Remove the planetary gear.






3. Remove the snap ring, then remove the shaft.






4. Separate shock absorber bearing (A) from internal gear (B), and remove shock absorber (C).






9. Remove the screws, and remove the starter cover from the brush holder assembly.

NOTE: Separate the starter cover by pressing the brush holder assembly using the screws so that the assembly stays onto the armature side.






10. Remove the brush holder assembly from the armature.

NOTE: Expand the brush with your fingers while taking care not to scratch it.






11. Remove the armature from the yoke.






ASSEMBLY

1. Install the armature to the yoke.






2. Install the brush holder assembly to the armature.

NOTE: Expand the brush with your fingers while taking care not to scratch it.






3. Install the starter cover, and secure it to the brush holder assembly with the screws.






4. Assemble the shock absorber in the following procedures:
1. Apply grease to shock absorber (C), and assemble internal gear (B) to shock absorber bearing (A).

NOTE: Align with the claw position of internal gear to assemble the shock absorber bearing.






2. Assemble the shaft to the internal gear.

NOTE: Apply grease to the shaft sliding surfaces inside the internal gear.






3. Attach the snap ring to the shaft.

NOTE: Use new snap rings.






5. Assemble the planetary gear to the internal gear.
1. Apply grease to the planetary gear installation position.

Grease: DENSO HL50

2. Install the planetary gear to the pin.
3. Apply grease to the planetary gear, internal gear, and upper part of the pin.

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






4. Install the starter plate.






6. 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. Install stopper (B) to the shaft, then install snap ring (A).






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






7. Assemble the overrunning clutch, shock absorber, and shaft to the yoke as a single unit






8. Install the shift lever.

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






9. Install the starter housing, and tighten through bolts on both sides.






10. Install the starter seal.






11. Install the magnet switch assembly to the starter housing, and tighten the nuts.

NOTE: Apply grease to the shift lever installation position.






12. Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.