Overhaul
OVERHAUL1. REMOVE MAGNET SWITCH BODY
a. Remove the nut, then disconnect the lead wire from the magnet switch.
b. Remove the 2 screws which are used to secure the magnet switch to the starter drive housing.
c. Remove the magnet switch.
d. Remove the return spring and plunger from the starter drive housing.
2. REMOVE STARTER YOKE ASSEMBLY
a. Remove the 2 through bolts, then pull out the starter yoke together with the starter commutator end frame.
b. Remove the starter yoke from the starter commutator end frame.
3. REMOVE STARTER ARMATURE PLATE
a. Remove the starter armature plate from the starter yoke.
4. REMOVE STARTER COMMUTATOR END FRAME COVER
a. Using a screwdriver, remove the starter commutator end frame cover.
5. REMOVE STARTER ARMATURE ASSEMBLY
a. Using snap ring pliers, remove the snap ring.
b. Remove the washer and the starter armature from the starter commutator end frame.
6. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears from the starter center bearing clutch.
7. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Remove the starter center bearing clutch together with the starter drive lever set pin from the starter drive housing.
8. REMOVE STARTER DRIVE LEVER SET PIN
a. Remove the starter drive lever set pin from the starter center bearing clutch.
9. INSPECT MAGNET SWITCH BODY
a. Check the operation.
1. Push in the plunger, then check that it returns quickly to its original position.
If necessary, replace the magnet switch.
b. Check the resistance.
1. Using an ohmmeter, check that there is resistance between terminals 50 and C.
Standard: 1 Ohm or lower
If the result is not met, replace the magnet switch.
2. Using an ohmmeter, check that there is resistance between terminal 50 and the switch body.
Standard: 2.0 Ohm or lower
If the result is not met, replace the magnet switch.
10. INSPECT STARTER ARMATURE ASSEMBLY
a. Check the resistance.
1. Using an ohmmeter, check that there is resistance between the segments of the commutator.
Standard: 1 Ohm or lower
If the result is not met, replace the starter armature.
2. Using an ohmmeter, check that there is no resistance between the commutator and armature coil core.
Standard: 10 kOhm or higher
If the resistance is not as specified, replace the starter armature.
b. Check the commutator surface for dirt or burn.
If the surface is dirty or burnt, smooth the surface with 400-grit sandpaper or lather.
c. Check the commutator depth.
1. Using vernier calipers, measure the commutator depth.
Standard depth: 3.1 mm (0.122 in.)
Maximum depth: 3.8 mm (0.150 in.)
If the depth is greater than maximum, replace the starter armature.
11. INSPECT STARTER COMMUTATOR END FRAME ASSEMBLY
a. Check the brush length.
1. Using vernier calipers, measure the brush length.
Standard length: 9.0 mm (0.354 in.)
Minimum length: 4.0 mm (0.158 in.)
If the length is less than minimum, replace the starter commutator end frame.
b. Check the resistance.
1. Using an ohmmeter, measure the resistance between the positive (+) and negative (-) brushes.
Standard: 10 kOhms or higher
If the resistance is not as specified, repair or replace the brush holder.
12. INSPECT STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Check the operation.
1. Turn the clutch pinion gear clockwise, then check that it turns freely. Try to rotate the clutch pinion gear counterclockwise, then check that it locks.
If necessary, replace the starter center bearing clutch.
b. Check for wear or damage.
1. Check the gear teeth on the planetary gear, internal gear and starter clutch for wear or damage.
If worn or damaged, replace the starter center bearing clutch.
13. INSTALL STARTER DRIVE LEVER SET PIN
a. Install the starter drive lever set pin to the starter center bearing clutch as shown in the illustration.
14. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY
a. Install the starter center bearing clutch together with the starter drive lever set pin to the starter drive housing.
15. INSTALL PLANETARY GEAR
a. Apply grease to the planetary gears and planetary shaft pins.
b. Install the 3 planetary gears to the starter center bearing clutch.
16. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the washer and armature shaft.
b. Install the starter armature and washer to the starter commutator end frame.
c. Using snap ring pliers, install a new snap ring.
d. Check the snap ring length.
1. Using vernier calipers, measure the snap ring length.
Maximum length: 5.0 mm (0.197 in.)
If the length is greater than maximum, replace it with a new snap ring.
17. INSTALL STARTER COMMUTATOR END FRAME COVER
a. Install the starter commutator end frame cover to the starter commutator end frame.
18. INSTALL STARTER ARMATURE PLATE
a. Align the keyway of the starter armature plate with the key inside of the starter yoke, then install the armature plate to the starter yoke.
19. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the rubber with the cutout of the starter yoke, then install the starter commutator end frame to the starter yoke.
20. INSTALL STARTER YOKE ASSEMBLY
a. Align the key of the starter yoke with the keyway of the starter drive housing, then install the starter yoke to the starter drive housing.
b. Tighten the 2 through bolts.
Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
21. INSTALL MAGNET SWITCH BODY
a. Apply grease to the plunger and hook.
b. Hang the plunger hook of the magnet switch into the starter drive lever set pin.
c. Install the plunger and return spring.
d. Install the magnet switch with the 2 screws.
Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)
e. Connect the lead wire to terminal C with the nut.
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)