Overhaul

Starter:

DISASSEMBLY

1. REMOVE MAGNETIC SWITCH ASSEMBLY

a. Remove the nut and disconnect the lead wire from the magnetic switch assembly.

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

2. REMOVE STARTER YOKE ASSEMBLY

a. Remove the 2 through-bolts, and pull out the starter yoke assembly together with the starter commutator end frame assembly.

3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY

a. Remove the starter commutator end frame assembly from the starter yoke assembly.

4. REMOVE STARTER ARMATURE PLATE

a. Remove the starter armature plate from the starter yoke assembly.

5. REMOVE STARTER COMMUTATOR END FRAME COVER

a. Using a screwdriver, pry out the starter commutator end frame cover.

6. REMOVE STARTER ARMATURE ASSEMBLY

a. Using snap ring pliers, remove the snap ring and plate washer.
b. Remove the starter armature assembly from the starter commutator end frame assembly.

7. REMOVE PLANETARY GEAR

a. Remove the 3 planetary gears from the starter drive housing assembly.

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 washers and the armature shaft.
b. Install the starter armature assembly to the starter commutator end frame assembly.
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 starter commutator end frame cover to the starter commutator end frame assembly.

4. INSTALL STARTER ARMATURE PLAT

a. Insert the starter armature plate to the starter yoke assembly.

1. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.

5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

a. Align the rubber of the starter end frame assembly with the cutout of the starter yoke assembly.
b. Install the starter commutator end frame assembly to the starter yoke assembly.

6. INSTALL STARTER YOKE ASSEMBLY

a. Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.

b. Install the starter yoke assembly 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 assembly on 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)