Disassembly and Reassembly
DISASSEMBLY1. REMOVE FIELD FRAME AND ARMATURE
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)
b. Remove the 2 through bolts.
Torque:
1.2 kw, 1.4 kw type: 5.9 Nm (60 kg.cm, 52 in.lb)
1.8 kw type: 9.3 Nm (95 kg.cm, 82 in.lb)
c. Pull out the field frame with the armature from the magnetic switch assembly.
NOTE: At the time of assembly, please refer to the following item.
Align the protrusion of the field frame with cutout of the magnetic switch.
d. Remove the O-ring.
HINT: At the time of assembly, please refer to the following item.
Use a new O-ring.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
a. Remove the 2 screws.
Torque:
1.2 kw, 1.4 kw type: 5.9 Nm (60 kg.cm, 52 in.lb)
1.8 kw type: 9.3 Nm (95 kg.cm, 82 in.lb)
b. Remove the starter housing, return spring, bearing, idler gear and clutch assembly from the magnetic switch assembly.
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
4. REMOVE BRUSH HOLDER
a. Remove the 2 screws and end cover from the field frame.
Torque:
1.2 kw, 1.4 kw type: 1.5 Nm (15 kg.cm, 13 in.lb)
1.8 kw type: 3.8 Nm (38 kg.cm, 34 in.lb)
b. Remove the O-ring from the field frame.
HINT: At the time of assembly, please refer to the following item.
Use a new O-ring.
c. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME
REPLACEMENT
1. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Press in a new bearing.
2. REPLACE FRONT BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
SST 09820-00030
NOTE: Be careful of the bearing installation direction.
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover
Remove the 3 bolts, lead clamp (1.8 kw type), end cover, gasket and plunger.
b. Inspect the contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove the terminal kit parts.
1. Using SST, loosen the terminal nuts.
SST 09810-38140
2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.
d. Install new terminal 30 kit parts.
1. Temporarily install new terminal insulator (inside).
NOTE: Be careful to install the terminal insulator in the correct direction.
2. Temporarily install new contact plate.
3. Temporarily install new terminal bolt.
4. Temporarily install new O-ring.
5. Temporarily install new packing and new terminal insulator (outside).
Install new packing to new terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing
6. Temporarily install new wave washer.
7. Temporarily install new terminal nut.
e. Install new terminal C kit parts.
1. Temporarily install new terminal insulator (inside).
2. Temporarily install new contact plate.
3. Temporarily install new terminal bolt.
4. Temporarily install new O-ring.
5. Temporarily install new terminal insulator (outside).
6. Temporarily install new wave washer.
7. Temporarily install new terminal nut.
NOTE: Be careful to install the terminal insulator (inside) in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten the terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kg, 221 lb)
Gauge Pressure:
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied.
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST; tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 Nm (170 kg.cm, 13 ft.lb)
NOTE: If the nut is over tightened, It may cause cracks on the inside of the insulator.
h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall the plunger, new gasket, end cover and lead clamp (1.8 kw type) with the 3 bolts.
Torque:
1.2 kw, 1.4 kw type: 2.5 Nm (25 kg.cm, 22 in.lb)
1.8 kw type: 3.6 Nm (35 kg.cm, 30 in.lb)
REASSEMBLY
Reassembly is In the reverse order of disassembly.
HINT: At the time of assembly, please refer to the following item.
Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.