Disassembly and Reassembly

DISASSEMBLY




1. REMOVE MAGNETIC SWITCH
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
b. Remove the 2 screws 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.
d. Remove the return spring and plunger.

2. REMOVE FIELD FRAME AND ARMATURE




a. Remove the 2 through bolts, and pull out the field frame together with the armature.
b. Remove the field frame from the commutator end frame.




c. Remove the plate from the field frame.




3. REMOVE COMMUTATOR END FRAME
a. Using a screwdriver, remove the cover.
b. Using snap ring pliers, remove the snap ring and plate washer.
c. Remove the armature from the commutator end frame.




4. REMOVE PLANETARY GEAR
Remove the 3 planetary gears.

REASSEMBLY

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

1. INSTALL PLANETARY GEAR
a. Apply grease to the planetary gears and pin parts of the planetary shaft.
b. Install the 3 planetary gears.

2. INSTALL ARMATURE




a. Apply grease to the washer and armature shaft.
b. Install the armature shaft to the commutator end frame.
c. Using snap ring pliers, install the washer and new snap ring.




d. Using vernier calipers, measure the snap ring.

Maximum length: 5.0 mm (0.1969 in.)

If the length is greater than the maximum, replace the snap ring with a new one.

3. INSTALL FIELD FRAME AND END FRAME WITH ARMATURE




a. Align the cutout of the plate with the protrusion inside the of the field frame, and install the plate.




b. Align the commutator rubber end frame with armature and the cutout of field frame.




c. Align the field frame with the cutout of starter housing.




d. Install the starter housing with the 2 through bolts.

Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf)

4. INSTALL MAGNETIC SWITCH




a. Apply grease to the plunger and hook.
b. Hang the plunger hook of the magnetic switch to the drive lever.
c. Install the plunger and return spring.
d. Install the magnetic switch with the 2 screws.

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)




e. Connect the lead wire to the terminal with the nut.

Torque: 6.5 N.m(66 kgf.cm, 58 in.lbf)