Overhaul

Starter:

Starter:

Starter:

Starter:

DISASSEMBLY

1. REMOVE STARTER YOKE ASSEMBLY




a. Remove the nut and disconnect the lead wire from terminal C.
b. Remove the 2 through bolts.
c. Pull out the starter yoke with the armature.
d. Remove the O-ring from the starter yoke.

2. REMOVE STARTER BRUSH HOLDER ASSEMBLY




a. Remove the 2 screws, 2 O-rings and end cover from the field frame.
b. Remove the O-ring from the field frame.




c. Disconnect the 2 starter yoke brushes from the brush holder.
1. Using a screwdriver, pull back the spring.
2. Disconnect the brush from the brush holder.

d. Remove the brush holder from the starter yoke.

3. REMOVE STARTER ARMATURE ASSEMBLY
a. Remove the starter armature from the starter yoke.

4. REMOVE STARTER CLUTCH SUB-ASSEMBLY




a. Remove the 2 screws and starter housing.




b. Remove the return spring, idler gear, clutch roller, retainer and starter clutch from the starter housing.




c. Using a magnetic finger, remove the steel ball from the clutch shaft hole.

REASSEMBLY

1. INSTALL STARTER CLUTCH SUB-ASSEMBLY
a. Apply grease to the steel ball, return spring, clutch rollers and starter idler pinions.
b. Install the steel ball.
c. Install a new O-ring to the starter housing.
d. Insert the return spring into the magnet starter switch hole.




e. Install the starter clutch, idler gear, retainer and clutch roller.




f. Install the starter housing to the magnet switch with the 2 screws.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

2. INSTALL STARTER ARMATURE ASSEMBLY
a. Install the starter armature to the starter yoke.

3. INSTALL STARTER BRUSH HOLDER ASSEMBLY




a. Align the claw of the brush holder with the claw groove of the starter yoke.
b. Place the brush holder on the starter yoke.
c. Install the 2 starter yoke brushes to the brush holder.
1. Using a screwdriver, pull back the spring.
2. Install the brush to the brush holder.

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

d. Install a new O-ring to the groove of the starter yoke.




e. Install the end cover with 2 new O-rings and the 2 screws.

Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)

4. INSTALL STARTER YOKE ASSEMBLY
a. Install a new O-ring to the groove of the starter yoke.




b. Align the protrusion of the starter yoke with the groove of the magnetic switch.




c. Install the starter yoke with the 2 through bolts.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

d. Connect the lead wire to terminal C with the nut.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)