Overhaul

Starter:

Starter:

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 plunger from the starter drive housing.




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




b. Remove the starter yoke from the commutator end frame.




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




4. REMOVE STARTER COMMUTATOR END FRAME COVER
a. Using a screwdriver, pry out the commutator end 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 starter drive housing.

REASSEMBLY

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




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 starter 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 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. Insert the armature plate to the starter yoke.
b. Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.




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




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




b. Install the starter yoke with the 2 through-bolts.

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