Disassembly and Reassembly

COMPONENTS FOR DISASSEMBLY AND ASSEMBLY

STARTER DISASSEMBLY
1. REMOVE DUST PROTECTOR

2. REMOVE FIELD FRAME AND ARMATURE




(a) Remove the nut and disconnect the lead wire from the magnetic switch terminal.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
(b) Remove the 2 through bolts.
Torque: 9.3 N.m (94 kgf.cm, 82 in.lbf)




(c) Pull out the field frame together with the armature.

ASSEMBLY NOTE: Align the protrusion of the field frame with the groove of the magnetic switch.

(d) Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.

3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR




(a) Remove the 2 screws.
Torque: 9.3 N.m (94 kgf.cm. 82 in.lbf)




(b) Remove these parts from the magnetic switch:
(1) Starter housing
(2) Return spring
(3) Idler gear
(4) Bearing
(5) Starter clutch assembly

ASSEMBLY HINT: Apply grease to the return spring and insert the return spring into the clutch shaft hole.





4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.

ASSEMBLY HINT: Apply grease to the steel ball and insert the steel ball into the clutch shaft hole.

5. REMOVE BRUSH HOLDER





(a) Remove the 2 screws and end cover from the field frame.
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
(b) Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.





(c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes and remove the brush holder.

ASSEMBLY NOTE: Check that the positive (+) lead wires are not grounded.

6. REMOVE ARMATURE FROM FIELD FRAME