Overhaul

Starter

DISASSEMBLY

1. Loosen the nuts fastening the magnet switch assembly M terminal, then disconnect the harness from the terminal.






2. Remove the screws fastening the magnet switch assembly, then remove the magnet switch assembly from the starter housing assembly.






3. Remove screws (A) of the brush holder assembly, and through bolts (B) on both sides, and remove the starter cover assembly.






4. Remove the brush holder assembly from the armature assembly.

NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.






5. Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.






6. Separate the armature assembly and yoke assembly.






7. Remove the pinion gear from the internal gear assembly.






8. Remove the rubber seal (A), plate (B), and rubber seal (C).






9. Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one piece.









10. Use the following procedures to remove the overrunning clutch from the shaft.
1. Use an appropriate tool (such as correctly sized socket wrenches) to lightly tap on the stopper to remove it from the snap ring.






2. Remove snap ring (A) from the shaft, and remove stopper (B).






3. Remove the overrunning clutch from the shaft.






11. Separate the internal gear assembly and shaft.






ASSEMBLY

1. Apply grease to the shaft sliding surfaces of the internal gear assembly.

Grease: Marutemp #6129 or equivalent

2. Assemble the shaft to the internal gear assembly.






3. Use the procedures below to assemble the overrunning clutch.
1. Apply grease to the splines of the shaft.

Grease: Marutemp #6129 or equivalent

2. Attach the overrunning clutch to the shaft.






3. Pass stopper (B) through the shaft assembly, and attach snap ring (A).






NOTE: Use new stoppers and snap rings.

4. Using a press, pressure fit stopper (B) into snap ring (A).






4. Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.

NOTE: Apply grease to the moving parts of the shift lever.






5. Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.

NOTE:
- Apply grease evenly to the contact surfaces of each gear.
- Be careful that no debris becomes attached.






6. Attach rubber seal (A), plate (B), and rubber seal (C).






7. Assemble the armature assembly to the yoke assembly.






8. Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.

NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.









9. Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.

NOTE: Be careful not to damage the brushes.






10. Attach the starter cover assembly, and affix to the brush holder assembly with screws (A).

Tightening torque: 1.4 N.m (0.1 kgf.m, 1.0 ft.lb)

11. Tighten through bolts (B) on both sides.






12. Attach the magnet switch assembly to the starter housing assembly, and tighten the screws.






13. Attach the harness to the M terminal of the magnet switch assembly, and tighten the nuts.