Starter Motor: Service and Repair

MAGNETIC SWITCH

REMOVAL





NOTE: Before disassembling starting motor,be sure to put match mark as shown in the figure left so that any possible mistake can be avoided.





1) Disconnect wire (switch to motor) from magnetic switch terminal.





2) Remove magnetic switch assembly.





NOTE: Don't disassemble this switch.If defective,replace as a complete assembly.





INSTALLATION
Before installation,inspect plunger joint for wear and replace defective parts.
1) Apply grease.
2) Install switch assembly into front housing,referring to left figure especially for its vertical direction.And then tighten screws.
3) Connect wire from motor to magnetic switch terminal.
4) Check switch for operation.

MOTOR BRUSH

REMOVAL





1) Remove rear bracket.





2) Remove brush holder and brushes.





INSTALLATION
Install in reverse order of REMOVAL,noting the following.
1) Apply grease.
2) Install brush holder to armature while pushing 4 brushes outward.
3) Install rear bracket.
4) Check motor for operation.

REAR BUSH (BEARING)





REMOVAL
1) Remove rear bracket.
2) Remove rear bracket cap,and then remove rear bush.





INSTALLATION
1) Install rear bush as shown left.
2) Install rear bracket cap as shown left.
3) Apply grease.
4) Install rear bracket.

ARMATURE/YOKE





REMOVAL

NOTE: Before disassembling starting motor,be sure to put match marks at two locations (A & B) as shown in figure left so that any possible mistake can be avoided.





1) Remove magnetic switch.
2) Remove rear bracket.
3) Remove brush holder.
4) Remove armature and yoke.

INSTALLATION





Install in reverse order of REMOVAL,noting the following.
1) Apply grease.

NOTE: If ball of armature shaft came out when removed,be sure to apply grease to ball and put it back in.





2) Install armature into yoke.
3) Install yoke and armature into front housing while aligning match mark "B" provided before disassembly.
4) Install brush holder.
5) Install rear bracket.
6) Install magnetic switch.
7) Carry out PERFORMANCE TEST.

OVER-RUNNING CLUTCH





REMOVAL

NOTE: Before disassembling starting motor,be sure to put match marks at two locations (A & B) as shown in figure left so that any possible mistake can be avoided.





1) Remove magnetic switch assembly.
2) Remove rear bracket.
3) Remove brush holder and brushes.
4) Remove yoke and armature.





5) Remove packing and idle gears.





6) Remove seal rubber and plate.





7) Remove shaft assembly with lever.





8) Remove over-running clutch by removing rings.

INSTALLATION





Install in reverse order of REMOVAL,noting the following.
1) Apply grease.
2) Install over-running clutch assembly to gear shaft, using care for installing direction of gear shaft stop ring.





3) Insert shaft ass'y into front housing with lever positioned as shown left.





4) Install packing so that cuts in packing align with holes for through bolt in front housing.





5) Install plate and seal rubber to front housing.





6) Apply grease to ball and install ball into shaft hole.





7) Install yoke and armature to front housing by aligning match marks provided before removal.
8) Install brushes and brush holder.(For details,refer to steps 1) to 3) of BRUSH INSTALLATION.
9) Tighten rear bracket bolts and brush holder screws.





10) Install magnetic switch assembly and connect wire (switch to motor) to switch terminal.(For details, refer to steps 1) to 3) of MAGNETIC SWITCH INSTALLATION.)
11) Upon completion of assembly,carry out PERFORMANCE TEST.