Overhaul

STARTER

DISASSEMBLY

1. REMOVE REPAIR SERVICE STARTER KIT




a. Remove the nut and disconnect the lead wire from the repair service starter kit.




b. Remove the 2 screws which are used to secure the repair service starter kit to the repair service starter kit.

c. Remove the repair service starter kit.
d. Remove the return spring and the plunger from the repair service starter kit.




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




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




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




4. REMOVE DRIVE HOUSING STARTER BEARING COVER
a. Using a screwdriver, remove the drive housing starter bearing cover.




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




6. REMOVE PLANETARY GEAR
a. Remove the 3 planetary gears from the repair service starter kit.

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 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 DRIVE HOUSING STARTER BEARING COVER
a. Install the drive housing starter bearing cover to the starter commutator end frame.




4. INSTALL STARTER ARMATURE PLATE
a. Insert the starter 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 with the convex cutout of starter yoke.
b. Install starter commutator end frame to the starter yoke.




6. INSTALL STARTER YOKE ASSEMBLY
a. Align the key of the starter yoke with the keyway of repair service starter kit.




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

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




7. INSTALL REPAIR SERVICE STARTER KIT
a. Apply grease to the plunger and the hook.
b. Hang the plunger hook of the repair service starter kit to the drive lever.
c. Install the plunger and return spring.




d. Install the repair service starter kit with the 2 screws.

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




e. Connect the lead wire to the repair service starter kit with the nut.

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