Disassembly and Reassembly

DISASSEMBLY




1. REMOVE MAGNETIC SWITCH ASSEMBLY
a. Remove the nut and disconnect the lead wire from the magnetic switch.




b. Remove the 2 screws holding the magnetic switch to the starter drive housing.
c. Remove the magnetic switch.
d. Remove the return spring and plunge from the drive housing.




2. REMOVE STARTER YOKE ASSEMBLY
a. Remove the 2 through bolts, and pull out the yoke together with the commutator end frame.




b. Remove the yoke from the commutator end frame.




3. REMOVE STARTER ARMATURE PLATE
a. Remove the armature plate from the field frame.




4. REMOVE STARTER COMMUTATOR END FRAME COVER
a. Using a screwdriver, remove the frame cover.




5. REMOVE STARTER ARMATURE ASSEMBLY
a. Using snap ring pliers, remove the snap ring and plate washer.
b. Remove the armature from the commutator end frame.




6. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears from the drive housing.


REASSEMBLY




1. INSTALL PLANETARY GEAR
a. Apply grease to the planetary gears and pin parts of the planetary shaft.
b. Install the 3 planetary gears.




2. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the plate washer and the armature shaft.
b. Install the armature to the starter commutator end frame.
c. Using snap ring pliers, install the plate washer and a new snap ring.




d. Using a vernier caliper, measure the length of the snap ring.

Maximum length: 5.0 mm (0.197 in.)

If the length is greater than the maximum, replace it with a new snap ring.




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




4. INSTALL STARTER ARMATURE PLATE
a. Align the keyway of the starter plate with the key inside the yoke, and install the plate.




5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the rubber of the end frame with the cutout of the yoke.
b. Install the end frame to the yoke.




6. INSTALL STARTER YOKE ASSEMBLY
a. Align the protrusion of the yoke with the cutout of the drive housing.




b. Install the yoke with the 2 through bolts.

Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)

7. INSTALL MAGNETIC SWITCH ASSEMBLY
a. Apply grease to the plunger and the hook.




b. Hang the plunger hook of the magnetic switch to the drive lever.
c. Install the plunger and return spring.




d. Install the magnetic switch with the 2 screws.

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)




e. Connect the lead wire to the magnetic switch with the nut.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)