Starter Reassembly

1. Cleaning

(a) Clean the field frame, gear reduction housing, etc. using compressed air to blow off any dirt and particles.

NOTE:
Always wear eye protection when using the compressed air.





2. Apply Grease

(a) Apply the supplied grease onto the idler gear and on the gear reduction housing surface where the new magnetic switch assembly contacts.

NOTE:
Do not apply grease in the area of the fastener holes in the gear reduction housing.





3. Assemble the Gear Reduction Housing and the New Magnetic Switch Assembly as Shown

(a) Assemble the new magnetic switch assembly onto the gear reduction housing assembly straight down.

NOTE:
Don't let the roller bearings, idler gear, or clutch assembly fall out. Confirm the steel ball and spring remains in the starter clutch assembly. Be careful not to damage plastic connector on new magnetic switch assembly.





4. Tighten the Housing with 2 New T30 Torx Bolts

(a) Install the new Torx bolts supplied with the magnetic switch assembly and tighten bolts as shown.

Torque: 9.3 N-m (95 kg-cm, 82 in-lb)

NOTE:
Use protective vise jaws or shop towels in the vise to avoid damaging the magnetic switch housing. Do not damage the magnetic switch assembly by overtightening the vise.





5. Assemble the Field Frame with the Armature

(a) Align the protrusion of the field frame with the groove of the magnetic switch, and assemble the field frame with the armature to the magnetic switch and gear reduction housing.

NOTE:
Be sure the 0-ring is in good condition and is in place on the field frame.





(b) Tighten the 2 through bolts evenly.

Torque: 12.7 N-m (130 kg-cm, 10 ft-lb)

6. Reconnect the Lead Wire

(a) Pull dust protector away from the nut to prevent pinching, reconnect the lead wire to the magnetic switch terminal and secure the dust protector.

Torque: 5.9 N-m (60 kg-cm, 52 in-lb)





7. Starter Performance Test.

(a) Perform a no-load performance test using a fully charged battery, the starter switch SST and your VAT.

(b) Connect a battery cable from the positive battery terminal to the battery cable terminal on the starter. Use the wing nut provided with the starter switch SST to attach the cable to the starter.

(c) Connect a ground cable from the negative battery terminal to the starter housing.





(d) Connect the VAT positive and negative clamps onto the battery, and the inductive power test pick-up to the negative battery cable close to battery terminal with the arrow facing towards the battery.

(e) Connect the starter switch SST from the positive battery terminal to the plug-in terminal on the starter magnetic switch.





(f) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Confirm that the ammeter shows the specified current:

100Amps or less at approximately 11.5 Volts.

NOTE:
Replace the starter If it does not spin or draws more than 100 A.