Disassembly and Assembly

Starter

DISASSEMBLY




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




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




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







4. Remove the through-bolts of bolt side, and then detach the end frame and armature from yoke as a unit.




5. Remove the end frame cover.
6. Remove the snap ring.







7. Remove the space ring.
8. Remove the armature from end frame.




9. Remove the screws.




10. Remove the brush holder assembly from end frame.




11. Remove the yoke from front bracket.




12. Remove the armature plate from the yoke.




13. Remove the rubber seal and planetary gear.




14. Remove the shaft assembly, overrunning clutch and lever from front bracket as a unit.
15. Remove the overrunning clutch from shaft assembly as follows:
1. Remove the stopper from snap ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).




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




16. Remove the snap ring.




17. Remove the shock absorber bearing, wave washer and internal gear from shaft.




18. Remove the front bearing from front bracket.
1. Set an appropriate tool (dia 13 mm) to front bearing.
2. Using a press, remove the front bearing.




19. Remove the oilless bearing from shock absorber bearing.
1. Set an appropriate tool (dia 20 mm) to oilless bearing.
2. Using a press, remove the oilless bearing.




20. Remove the rear bearing from end frame.
1. Set an appropriate tool (dia 16 mm) to rear bearing.
2. Using a press, remove the rear bearing.

ASSEMBLY

1. Press-fit the rear bearing into end frame.
1. Set an appropriate tool (dia 22 mm) to rear bearing.




2. Press-fit the rear bearing using a press.

NOTE:
- Use a new bearing.
- Use a flat base.
- Press-fit the bearing outer ring until it contact to the base bottom.

2. Press-fit the oilless bearing into shock absorber bearing.
1. Set an appropriate tool (dia 20 mm) to oilless bearing.




2. Press-fit the oilless bearing using a press.

NOTE:
- Use a new bearing.
- Use a flat base.
- Press-fit the bearing outer ring until it contact to the base bottom.




3. Press-fit the front bearing into front bracket.
1. Set the front bearing into front bracket.
2. Set an appropriate tool (2.0 mm thickness plate) to front bracket, and press-fit the front bearing using a press.

NOTE:
- Use a new bearing.
- Measure the protrusion of front bearing after press-fitting, to check if it is within standard value.




4. Assemble the internal gear and wave washer to shock absorber bearing.

NOTE: Align with the pawl position of shock absorber bearing to install internal gear.




5. Assemble the washer and internal gear to shaft.

NOTE: Apply grease to the both sides of the shaft spline and washer.




6. Assemble the snap ring.




7. Assemble the overrunning clutch to shaft.

NOTE: Apply grease to the stop ring entire perimeter.

8. Install the stopper to shaft as follows:




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

NOTE: Use new snap rings.




2. Press-fit the stopper to snap ring using a press.

9. Install the shaft assembly to front bracket.




1. Apply grease to the sliding part (A) of lever pin and the pole piece (B) of arm.




2. Insert the lever arm into the position on over running clutch as shown in the figure.




3. Align the shaft assembly to the position on front bracket as shown in the figure.




10. Install the rubber seal.
11. Install the planetary gear.




1. Apply a grease to the pin (A) and bushing (B).
2. Assemble the planetary gear to pin.




3. Apply grease to the planetary gear clearance (A) and pin upper part (B).

NOTE:
- Apply grease so that it contacts each gear.
- be careful not to allow dirt to get in.







12. Assemble the brush assembly to end frame.

NOTE:
- Be careful not to allow grease to get on brush.
- Align the rubber seal part with end frame groove.

13. Install the armature to end frame.

NOTE:
- Apply grease to the rear bearing inner circumference.
- Be careful not to allow grease to attach to commutator.

Grease: DENSO HL50







14. Set the space ring, then assemble the snap ring.

NOTE:
- Use new snap rings.
- Check the dimension of (A) in the figure after assembling snap ring. If it exceeds 5.0 mm (0.20 in), assemble a new snap ring again.




15. Install the end frame cover.




16. Assemble the armature plate to yoke.

NOTE:
- Align the rotation stopper of armature plate with the drive out part of yoke inner circumference.
- Be careful of the assembly direction of armature plate.







17. Assemble the armature to yoke.

NOTE:
- Be careful not to allow armature plate to move. It is recommendable to support with cylindrical pipe as shown in the figure.
- Align the positions of cutout portion of yoke with the rubber part of end frame.
- Be careful not to damage the magnet.




18. Assemble the yoke to front bracket.

NOTE:
- Apply grease to the end surface of yoke (mating surface with front bracket).
- Align the drive out position of yoke outer perimeter with the cutout portion of front bracket.




19. Tighten the through bolts on both sides.




20. Install the rear cover.
21. Install the magnet switch assembly to front bracket.




1. Assemble the plunger hook to lever.

NOTE: Apply grease to the plunger hook and sleeve inner circumference.







2. Assemble the plunger spring and magnet switch to front bracket.

NOTE: Apply grease to the end surface of magnet switch as shown in the figure.




3. Tighten the bolt.




22. Connect the harness to terminal M of magnet switch assembly.