Overhaul

DISASSEMBLY




1. REMOVE MAGNET SWITCH BODY
a. Remove the nut, then disconnect the lead wire from the magnet switch.




b. Remove the 2 screws [B] 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.

REASSEMBLY




1. 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.




2. 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.




3. 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.




4. 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.




5. INSTALL STARTER COMMUTATOR END FRAME COVER
a. Install the starter commutator end frame cover to the starter commutator end frame.




6. 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.




7. 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.




8. 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)




9. 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)