Overhaul
StarterDISASSEMBLY
1. STI MODEL
1. Disconnect cable from terminal M (A) of the 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.
2. EXCEPT FOR STI MODEL
1. Disconnect cable from terminal M of the magnet switch assembly.
2. Remove the magnet switch assembly from the starter housing assembly.
3. Remove screws (A) of the brush holder assembly, and through bolts (B) on both sides, and remove the starter cover assembly.
4. Remove the brush holder assembly from the armature assembly.
NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.
5. Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.
6. Separate the armature assembly and yoke assembly.
7. Remove the pinion gear from the internal gear assembly.
8. Remove seal rubber (A), plate (B), and seal rubber (C).
9. Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one unit.
10. 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.
11. Separate the internal gear assembly and shaft.
ASSEMBLY
1. STI MODEL
1. Use the following procedures to install the shaft.
1. Apply grease to the shaft sliding surfaces of the internal gear assembly.
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.
Grease: DENSO HL50
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.
Grease: DENSO HL50
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.
Tightening torque: 6 N.m (0.6 kgf.m, 4.4 ft.lb)
9. Attach the magnet switch assembly to the starter housing assembly.
Tightening torque: 7.5 N.m (0.8 kgf.m, 5.5 ft.lb)
10. Connect terminal M (A) to magnet switch assembly.
Tightening torque: 10 N.m (1.0 kgf.m, 7.4 ft.lb)
2. EXCEPT FOR STI MODEL
1. Apply grease to the shaft sliding surfaces of the internal gear assembly.
Grease: Multemp #6129 or equivalent
2. Assemble the shaft to the internal gear assembly.
3. Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.
Grease: Multemp #6129 or equivalent
2. Install the overrunning clutch to shaft.
3. Pass stopper (B) through the shaft assembly, and attach snap ring (A).
NOTE: Use new stoppers and snap rings.
4. Using a press, pressure fit stopper (B) into snap ring (A).
4. Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.
NOTE: Apply grease to the moving parts of the shift lever.
Grease: Multemp #6129 or equivalent
5. Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.
NOTE:
- Apply grease evenly to the contact surfaces of each gear.
- Be careful that no debris becomes attached.
6. Install seal rubber (A), plate (B), and seal rubber (C).
7. Assemble the armature assembly to the yoke assembly.
8. Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.
NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.
9. Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.
NOTE: Be careful not to damage the brushes.
10. Secure starter cover assembly to the brush holder assembly with screws (A).
Tightening torque: 1.4 N.m (0.1 kgf.m, 1.0 ft.lb)
11. Install through bolts (B) on both sides.
Tightening torque: 6 N.m (0.6 kgf.m, 4.4 ft.lb)
12. Attach the magnet switch assembly to the starter housing assembly.
Tightening torque: 7.5 N.m (0.8 kgf.m, 5.5 ft.lb)
13. Attach the cable to the terminal M of the magnet switch assembly, and secure with nuts.
Tightening torque: 10 N.m (1.0 kgf.m, 7.4 ft.lb)
