Disassembling and Assembling Starting, Motor/Transmission Gear

Disassembling And Assembling Starting, Motor/Transmission Gear


NOTE: Starting motor removed







Unscrew heat-protection plate (if installed).
Unscrew bracket.
Check spacers.







Remove solenoid switch.
Unscrew both studs.

Installation:
Clean all parts thoroughly before assembling.








Separate motor (1) and transmission (2).

Installation:
Groove (3) should be aligned with rubber part (4).







Take off protective cap.
Remove retainer (1) and shims (2).

Installation:
Check axial clearance, correcting if necessary.







Check armature shaft, removing burrs if necessary.
Take off cover.







Insert a 22 mm wrench socket or piece of pipe (with an outside diameter of approx. 30 mm) in order to prevent the carbon brushes from springing out.







Installation:
Use wrench socket or pipe again to make installation easier.

Mount entire assembly on transmission case and then tighten cable socket.







Take off cover and rubber block.







Pull out transmission unit.
Take toothed ring off planetary transmission and release.
1. Planetary transmission
2. Release
3. Pinion
4. Transmission case







Installation:
Openings and bores must be aligned.







Check bearing and, if necessary, drive it out with a suitable mandrel.

Installation:
Lubricate new bearing with grease and press it in.

A = approx. 1 mm







Turn drive pinion against stop.
Pinion will be very easy to turn if one-way clutch is worn.
Check bearing sleeve and teeth of pinion for wear.







Knock back thrust ring (1). Pull off retainer (2) in forward direction.
If applicable, remove burrs and take off drive pinion.

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







Pull off circlip (1) and take off washers.
1. Circlip
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 and, if necessary, remove it with a suitable puller.
Check planet gears for wear.

Installation:
Lubricate sleeve with oil after pressing it in.