Overhaul

Starter:

DISASSEMBLY

1. REMOVE STARTER YOKE ASSEMBLY




a. Remove the nut, then disconnect the lead wire from terminal C.
b. Remove the 2 through bolts, then pull the starter yoke and starter commutator end frame out together.
c. Remove the O-ring from the starter yoke.

2. REMOVE STARTER BRUSH HOLDER ASSEMBLY




a. Remove the 2 screws, then remove the end cover from the starter yoke.
b. Remove the O-ring from the starter yoke.




c. Using a screwdriver, hold the spring back and disconnect the 4 brushes from the brush holder.
d. Remove the brush holder from the starter yoke.

3. REMOVE STARTER ARMATURE ASSEMBLY

NOTE: Turn the armature and check that it turns freely.

4. REMOVE STARTER CLUTCH SUB-ASSEMBLY




a. Remove the 2 screws, then remove the starter drive housing.

NOTE: Do not drop the starter idle gear pinion, starter idle gear retainer or starter idle gear clutch roller.




b. Remove the starter idle gear pinion from the starter drive housing.
c. Remove the starter idle gear retainer from the starter drive housing.
d. Remove the starter idle gear clutch roller from the starter drive housing.
e. Remove the starter clutch from the starter drive housing.
f. Remove the starter magnet switch return spring from the starter drive housing.




g. Using a magnetic finger, remove the steel ball from the clutch shaft hole.

REASSEMBLY

1. INSTALL STARTER CLUTCH SUB-ASSEMBLY




a. Apply grease to the steel ball and install it onto the starter drive housing.
b. Apply grease to the magnet switch return spring and install it onto the starter drive housing.
c. Apply grease to the starter clutch, and install it onto the starter drive housing.
d. Apply grease to the starter idle gear clutch roller and install it onto the starter idle gear retainer.
e. Apply grease to the starter idle gear retainer and install it onto the starter idle gear pinion.
f. Apply grease to the starter idle gear pinion and install it onto the starter drive housing.




g. Install the starter drive housing with the 2 screws.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

2. INSTALL STARTER ARMATURE ASSEMBLY

a. Apply grease to the bearings and install it onto the starter yoke.

3. INSTALL STARTER BRUSH HOLDER ASSEMBLY




a. Place the brush holder assembly on the starter yoke.
b. Using a screwdriver, install the 4 brushes.
c. Install a new O-ring onto the groove of the field frame.




d. Install the end frame with the 2 screws.

4. INSTALL STARTER YOKE ASSEMBLY




a. Install a new O-ring onto the groove of the starter yoke.
b. Align the key of the starter yoke with the groove of the magnet starter switch.




c. Tighten the 2 through bolts.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)

d. Connect the lead wire to terminal C with the nut.

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