Disassembly and Reassembly

STARTER MOTOR DISASSEMBLY AND ASSEMBLY





DISASSEMBLY

1. REMOVE DUST PROTECTORS
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:
1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)





c. Pull out the field frame with the armature from the magnetic switch.

REASSEMBLY HINT: Align the protrusion of the fields frame with cutout of the magnetic switch.

d. Remove the O-ring.

REASSEMBLY HINT: Use a new O-ring.

3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR





a. Remove the 2 screws.
Torque:
1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)





b. Remove these parts from the magnetic switch assembly:
1. Starter housing
2. Return spring
3. Bearing
4. Idler gear
5. Starter 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 and end cover from the field frame.
Torque:
1.4 kW type: 1.5 N.m (15 kgf.cm, 13 in.lbf)
2.0 kW type: 3.8 N.m (39 kgf.cm, 35 in.lbf)
b. Remove the O-ring from the field frame.

REASSEMBLY HINT: Use a new O-ring.





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

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

6. REMOVE ARMATURE FROM FIELD FRAME

REASSEMBLY
Reassembly is in the reverse order of disassembly.

HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.