Disassembly and Assembly

DISASSEMBLY

1. STARTER ASSEMBLY
1. Loosen the nut which holds the terminal M of switch assembly, and then disconnect the connector.




2. Remove the bolts which hold the switch assembly, and then remove switch assembly, plunger and plunger spring from starter as a unit.

NOTE: Be careful because the pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.





3. Remove both through-bolts and brush holder screws, and then detach the rear cover and brush holder.





4. Remove the armature and yoke from front bracket. The ball used as a bearing will come off from the armature end.

NOTE: Before removal of the yoke, put alignment marks on the yoke and front bracket.





5. Remove packing A, planetary gears, packing B and plate.




6. Remove the shaft assembly and overrunning clutch as a unit.

NOTE: Note the direction of the lever before removing.

7. Remove the overrunning clutch from shaft assembly as follows:
1. Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).




2. Remove the ring, stopper and clutch from shaft.

2. BRUSH HOLDER

NOTE: Only the brush holder of turbo MT model starter can be disassembled.





Slightly open the metal fitting while holding the insulating plate against the brush holder. Remove the insulating plate.
The brush and spring can be easily removed from the brush holder at this time.

ASSEMBLY
1. Assemble in the reverse order of disassembly.
2. Apply grease to the following parts before assembly.
- Front and rear bracket sleeve bearings
- Armature shaft gear
- Outer periphery of plunger
- Mating surfaces of plunger and lever
- Gear shaft splines
- Mating surfaces of lever and clutch
- Ball at armature shaft end
- Planetary gear