Disassembling and Assembling Starter

DISASSEMBLING AND ASSEMBLING STARTER







Remove solenoid switch.
Unscrew dust cap (2).
Take oft circlip (3), shims (4) and seal (5).

Installation:
Check axial play of armature, correcting with shims if necessary.






Unscrew housing bolts and take off cover.

Installation:
Align openings for housing bolts and insulator to each other. Check bearing sleeve, lubricating with oil before installing.






Lift springs and pull out carbon brushes.
Remove holder.

Installation:
Check carbon brushes and commutator for wear, replacing if necessary.






Remove pole housing.
Unscrew engaging lever bolt and remove rubber seal.






Lift out armature with drive pinion and engaging fork.

Installation:
Lubricate guide far engaging fork with grease.
Check bearing sleeve In drive bearing bracket, lubricating with all before installing.






Push back bearing race (1) with a piece of suitable pipe.
Pry circlip (2) apart and pull it off at the shaft.
Remove burrs with a file.
Take off drive pinion (3).


Installation:
Use a new circlip (2).
Lubricate bearing surface for drive pinion with grease.






Installation:
Check pinion for wear (on teeth, bearings and one-way clutch), replacing if necessary.






Check sleeve in intermediate bearing, replacing if necessary.






Pull out gearbox unit.
Take gear ring off of planet gearbox and release bearing.

1. Planet gearbox
2. Release bearing
3. Pinion
4. Gearbox






Installation:
Openings and bores must be aligned.






Check bearing, driving it out with a suitable size mandrel if necessary.


Installation:
Lubricate new bearing with grease and press it in.
Distance A = approx. 1 mm (0.039").






Turn drive pinion against the stop. The pinion can be turned very easily when the one-way clutch is worn excessively.
Check bearing sleeve and teeth of the pinion for wear.






Knock back thrust ring (1).
Pull off retainer (2) forward.
Remove burrs if applicable and then take off the drive pinion.

Installation:
Clean the pinion bearing surface thoroughly and lubricate with grease.






Pull off circlip (1).

Take off washers.
(2) Metal washer
(3) Plastic washer






Take off bearing cover (4) and washers (5).
Check bearing sleeve (6), replacing if necessary.

Installation:
Lubricate sleeve with oil after pressing it in.






Check bearing sleeve, removing it with a suitable puller If necessary. Check planet gears for wear.

Installation:
Lubricate sleeve with oil after pressing it in.