Disassembly and Reassembly

DISASSEMBLY

Starter Component:

1. REMOVE MAGNETIC SWITCH
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
b. Remove the 2 nuts holding the magnetic switch to the starter housing.




c. Pull the magnetic switch and while lifting the front part of the magnetic switch, release the plunger hook from the drive lever, then release the magnetic switch.




2. REMOVE FIELD FRAME AND ARMATURE
a. Remove the 2 through bolts.
b. Pull out the field frame together with the armature.
c. Remove the O-ring from the field frame.




3. REMOVE BRUSH HOLDER
a. Remove the 2 screws and end cover from the field frame.
b. Remove the O-ring from the field frame.




c. Using a screwdriver, hold the spring back and disconnect the brush holder. Disconnect the 4 brushes, and remove the brush holder.

4. REMOVE ARMATURE FROM FIELD FRAME

5. REMOVE DRIVE LEVER AND STARTER CLUTCH WITH SHOCK ABSORBER FROM STARTER HOUSING




6. REMOVE PLANETARY GEARS
Remove the plate, 3 planetary gears and plate washer.




7. REMOVE STARTER CLUTCH
a. Using a screwdriver, tap in the stop collar towards the starter clutch.
b. Using a screwdriver, pry off the snap ring.
c. Remove the stop collar and starter clutch from the planetary carrier shaft.




8. REMOVE PLANETARY CARRIER SHAFT AND INTERNAL GEAR
a. Using snap ring pliers, remove the snap ring and plate washer.
b. Remove the planetary carrier shaft and plate washer.




c. Align the hollow of the internal gear with the protrusion inside the shock absorber, and remove the internal gear.

REASSEMBLY





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

1. INSTALL INTERNAL GEAR AND PLANETARY CARRIER SHAFT
a. Apply grease to the internal gear touching the shock absorber and planetary gears.




b. Align the hollow of the internal gear with the protrusion inside the shock absorber.
c. Insert and turn the internal gear so that it interlocks with the shock absorber.




d. Apply turbine oil to the center bearing.
e. Apply grease to the plate washer, and install it to the planetary carrier shaft.
f. Install the planetary carrier shaft to the shock absorber.




g. Using snap ring pliers, install the plate washer and snap ring.




2. INSTALL STARTER CLUTCH

a. Apply grease to the bushing and spline of the starter clutch stop collar.
b. Place the starter clutch and stop collar on the planetary carrier shaft.




c. Apply grease to the snap ring, and install it to the planetary carrier shaft groove.
d. Using a vise, compress the snap ring.




e. Hold the starter clutch, tap the planetary carrier shaft and install the stop collar onto the snap ring with a plastic- faced hammer.




3. INSTALL PLANETARY GEARS
a. Apply grease to the planetary gears and flange pin parts of the planet carrier shaft.
b. Install the plate washer and 3 planetary gears.
c. Align the cutout of the plate with the protrusion inside the shock absorber, and install the plate.




4. INSTALL DRIVE LEVER AND STARTER CLUTCH WITH SHOCK ABSORBER
a. Apply grease to the drive lever touching the starter pivot part of the drive lever.
b. Install the drive lever to the starter clutch.




c. Align the protrusion of the shock absorber with the cutout of the drive housing and install them.

5. PLACE ARMATURE INTO FIELD FRAME




6. INSTALL BRUSH HOLDER
a. Place the brush holder in position on the armature.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.

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

c. Install a new O-ring to the groove of the field frame.
d. Apply turbine oil to the bearing of the end cover.
e. Install the end cover to the field frame with 2 screws.
Torque: 1.5 Nm (15 kg.cm, 13 in.lb)




7. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
a. Install a new O-ring to the groove of the field frame.
b. Align the cutout of the field frame with the protrusion of the shock absorber.
c. Install the field frame and armature assembly with the 2 through bolts.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)




8. INSTALL MAGNETIC SWITCH
a. Hang the plunger of the magnetic switch to the drive lever from the upper side.
b. Install the magnetic switch with the 2 nuts.
Torque: 8.3 Nm (85 kg.cm, 73 in.lb)
c. Connect the lead wire to the terminal, and install the nut.
Torque: 9.8 Nm (100 kg.cm, 87 in.lb)