Overhaul

DISASSEMBLY

1. STARTER ASSEMBLY
1. Loosen the nuts fastening the magnet switch assembly M terminal, then disconnect the connector.
2. Remove the bolts fastening the magnet switch assembly, then remove the magnet switch assembly, plunger and plunger spring as a unit from the starter.

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






3. Remove the bolts passing through both sides, and the brush holder screws, then remove rear cover (B) and brush holder (A).






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

NOTE: Before removing the yoke, put alignment marks on the yoke assembly and front bracket.






5. Remove the gasket A, planetary gears, gasket B and plate.






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

NOTE: Note the direction of the lever before removing.






7. Use the following procedures to remove the overrunning clutch from the shaft assembly.
1. Use the appropriate tool (such as the right size of socket wrench) to lightly tap on the stopper to remove it from the ring.
2. Remove the ring, spacer, and clutch from the shaft.






2. BRUSH HOLDER

NOTE: Slightly open the metal fitting while holding the insulating plate against the brush holder, to remove the insulating plate 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