Disassembly and Assembly

DISASSEMBLY

STARTER ASSEMBLY




1. Loosen the nut which holds terminal M of switch assembly, and then disconnect the connector.




2. Remove the bolts which hold switch assembly, and then remove the switch assembly, plunger and plunger spring from starter as a unit.

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




3. Remove both the nuts, and then remove rear cover set.




4. Remove both through-bolts and brush holder screws, and then detach the rear cover and brush holder.




5. Remove the armature and yoke from front bracket.




6. Remove the packing A, planetary gear and packing B.




7. Remove the plate.




8. Remove the shaft assembly and overrunning clutch from front bracket as a unit.

NOTE: Check the following points before removal.
- Lever direction
- Position of internal gear assembly

9. Remove the overrunning clutch from shaft assembly as follows:
1. Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).




2. Remove the ring, stopper and clutch from shaft.

ASSEMBLY

NOTE: Apply grease to the following parts before assembly.
- Sleeve bearing
- Pinion shaft rotational portion
- Shaft spline portion
- Inside of reduction system
- Lever fulcrum/Clutch rotational portion

1. Install the overrunning clutch to shaft assembly.
2. Install the stopper to shaft assembly as follows.




1. Insert the ring into the shaft groove by lightly tapping it with an appropriate tool (such as a fit socket wrench).




2. Install the stopper to ring using a press.

3. Install the shaft assembly to front bracket while taking care of the following points.




1. Lever direction




2. Internal gear position




4. Install the plate.
5. Install the planetary gear.




6. Install packing A and B while taking care of installing positions.
7. Install the armature to yoke.




8. Install the yoke to front bracket matching front bracket to groove of yoke.
9. Install the brush holder to yoke as follows.




1. Press the brush down into brush holder, and then fix the brush in that position using an appropriate tool (such as a fit socket wrench).




2. Match the brush holder to groove of yoke, and then slide the brush holder into yoke to install.




10. Install the rear cover matching it's groove to brush holder.




11. Install rear cover set.
12. Install the switch assembly to front bracket as follows.
1. Insert the plunger and plunger spring into switch assembly.




2. Hook the plunger protrusion on lever edge to install plunger to front bracket.




13. Connect the connector to terminal M of switch assembly.