Disassembly and Assembly

DISASSEMBLY
1. STARTER ASSEMBLY




1. Loosen nut which holds terminal M of switch assembly, and disconnect connector.
2. Remove bolts which hold switch assembly, and remove switch assembly, plunger and plunger spring from starter as a unit.

CAUTION: Be careful because pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.




3. Remove both through-bolts and brush holder screws, and detach rear bracket and brush holder.




4. Remove armature and yoke. Ball used as a bearing will then be removed from the end of armature.

CAUTION: Be sure to mark an alignment mark on yoke and front bracket before removing yoke.




5. Remove packing A, three planetary gears, packing B and plate.




6. Remove shaft assembly and overrunning clutch as a unit.

CAUTION: Record the direction of lever before removing.




7. Remove overrunning clutch from shaft assembly as follows:
1. Remove stopper from ring by lightly tapping a fit tool placed on stopper.
2. Remove ring, stopper and clutch from shaft.




2. BRUSH HOLDER
Slightly open the metal fitting holding the insulating plate to the brush holder. Remove the insulating plate.

NOTE: The brush and spring can be easily removed from the brush holder at this time.

ASSEMBLY
Assembly is in the reverse order of disassembly procedures. Observe the following:
1. Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been overlooked.
2. Apply grease to the following parts during assembly.
- Front bracket sleeve bearing
- Armature shaft gear
- Outer periphery of plunger
- Mating surface of plunger and lever
- Gear shaft splines
- Mating surface of lever and clutch
- Ball at the armature shaft end
- Internal and planetary gears

3. After assembling parts correctly, check to be sure starter operates properly.