Disassembly and Assembly

DISASSEMBLY




1. Disconnect lead wire (A) from magnetic switch (B).




2. Remove through-bolts (A) from end frame (B).




3. Remove yoke (A) from magnetic switch (B).




4. Remove screws (A) securing end frame (B) to brush holder.




5. Separate yoke (A) from end frame (B).




6. Remove brush (A) by lifting up positive (+) side brush spring (B) using long-nose pliers.

CAUTION: Be careful not to damage brush and commutator.




7. Remove armature (A) from yoke (B).

CAUTION: Be careful not to drop armature.




8. Remove screws securing magnetic switch (A) to housing (B).




9. Remove housing (A) from magnetic switch (B).




10. Remove clutch (A) from housing (B).




11. Take out steel ball (A) from clutch (B).

CAUTION: Be careful not to lose steel ball.




12. Remove idle gear (A) from housing.




13. Remove retainer and roller (A) from housing.

CAUTION: Be careful not to drop retainer and roller.




14. Remove coil spring (A) from magnetic switch (B).

ASSEMBLY

Assemble in the reverse order of disassembly.
Observe the following:
1. Before assembling, lubricate disassembled parts at the points shown in "COMPONENT PARTS".

Grease:
ESSO BEACON 325
SHELL ALVANIA GREASE RA or equivalent

2. Assembling magnetic switch, clutch, and housing
To assemble, first install clutch to magnetic switch, then install idle gear, and finally install clutch.






CAUTION:
- Do not forget to install steel ball and coil spring to clutch.
- Attach bearing to idle gear beforehand.





3. Installing armature (A) to yoke (B)

CAUTION: Do not forget to put felt washer on armature shaft bearing.




4. Installing brushes
Assemble brush holder to yoke as shown, then assemble two yoke-side brushes to brush holder.




5. Installing end frame
When assembling end frame to yoke, align notched portion (A) of end frame with lead wire grommet (B).




6. Installing yoke
When installing yoke to magnetic switch, align notch (A) of yoke with protrusion of magnetic switch.