Disassembly and Assembly

DISASSEMBLY

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




CAUTION: Be careful because the 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 the rear bracket and brush holder.
4. Remove the 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 the yoke and front bracket before removing the yoke.




5. Remove packing A, three planetary gears, packing B and plate.
6. Remove the shaft assembly and overrunning clutch as a unit.




CAUTION: Record the direction of the lever before removing.




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

ASSEMBLY
Assembly is in the reverse order of disassembly procedures. Do 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 and rear 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 the starter operates properly.