Disassembly and Reassembly

Starter Motor:

STARTER DISASSEMBLY







1. REMOVE DUST PROTECTOR


2. REMOVE FIELD FRAME AND ARMATURE
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)







b. Remove the 2 through bolts.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)







c. Pull out the field frame together with the armature.

ASSEMBLY HINT: Align the protrusion of the field frame with the groove of the magnetic switch.

d. Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.







3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR
a. Remove the 2 bolts.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)







b. Remove these parts from the magnetic switch:
1. Starter housing
2. Return spring
3. Idler gear
4. Bearing
5. Clutch assembly







4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.







5. REMOVE BRUSH HOLDER
a. Remove the 2 screws, 2 O-rings and end cover from the field frame.

ASSEMBLY HINT: Use 2 new O-rings.

Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)

b. Remove the O-ring from the field frame.

ASSEMBLY HINT: 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.

ASSEMBLY NOTE: Check that the positive (+) lead wires are not grounded.

6. REMOVE ARMATURE FROM FIELD FRAME


ASSEMBLY
Assembly is in the reverse order of disassembly.

HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.