Overhaul

Starter

DISASSEMBLY

1. Disconnect the terminal M from the magnet switch assembly.






2. Remove the magnet switch assembly from the starter housing assembly.






3. Remove screws (A) of the brush holder assembly, and through bolts (B) on both sides, and remove the starter cover assembly.






4. Remove the brush holder assembly from the armature assembly.

NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.






5. Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.






6. Separate the armature assembly and yoke assembly.






7. Remove the pinion gear from the internal gear assembly.






8. Remove seal rubber (A), plate (B), and seal rubber (C).






9. Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one unit.






10. Use the following procedures to remove the overrunning clutch from the shaft.
1. Use an appropriate tool (such as a fit socket wrench), and remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer.






2. Remove snap ring (A) from the shaft, and remove stopper (B).






3. Remove the overrunning clutch from the shaft.






11. Separate the internal gear assembly and shaft.






ASSEMBLY

1. Apply grease to the shaft sliding surfaces of the internal gear assembly.

Grease: Multemp #6129 or equivalent

2. Assemble the shaft to the internal gear assembly.






3. Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.

Grease: Multemp #6129 or equivalent

2. Install the overrunning clutch to shaft.






3. Pass stopper (B) through the shaft assembly, and attach snap ring (A).

NOTE: Use new stoppers and snap rings.






4. Using a press, pressure fit stopper (B) into snap ring (A).






4. Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.

NOTE: Apply grease to the moving parts of the shift lever.

Grease: Multemp #6129 or equivalent






5. Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.

NOTE:
- Apply grease evenly to the contact surfaces of each gear.
- Be careful that no debris becomes attached.

Grease: Molykote(R) AG650 or equivalent






6. Install seal rubber (A), plate (B), and seal rubber (C).






7. Assemble the armature assembly to the yoke assembly.






8. Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.

NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.









9. Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.

NOTE: Be careful not to damage the brushes.






10. Secure starter cover assembly to the brush holder assembly with screws (A).

Tightening torque: 1.4 N.m (0.1 kgf-m, 1.0 ft-lb)

11. Tighten through bolts (B) on both sides.

Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)






12. Attach the magnet switch assembly to the starter housing assembly.

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)






13. Attach the cable to the terminal M of the magnet switch assembly, and secure with nuts.

Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)