Disassembly and Reassembly

Disassembly

NOTE:
- Before disassembling starting motor, be sure to put match marks at 2 locations (A (magnetic clutch (1) and front housing (2)) and B (front housing (2) and yoke (3))) as shown in figure so that any possible mistake can be avoided.




- Do not clamp yoke in a vise or strike it with a hammer during repair operations.




1. Remove protector (2) (if equipped) and magnetic switch (1).






CAUTION: Don't disassemble this switch. If defective, replace as a complete assembly.




2. Remove bolts (1) shown in figure, then separate reduction gear assembly (2) from starting motor assembly.




3. To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).




4. Remove seal rubber (1) and plate (2).




5. Remove shaft assembly (1) with lever (2).




6. Loosen pinion stop ring (2) fixed by snap ring (1).




7. Remove snap ring (2) then pull out pinion stop ring (3) and over-running clutch (4) and internal gear (1).

Special tool
(A) : 09900-06107




8. Remove rear bracket (1) and brush holder.




9. Remove armature (1) from yoke (2) and then ball (3) from the end of armature shaft.




10. Remove brush holder (2) from rear bracket (1).




11. Remove brush springs (1) and brushes (2).




12. Remove rear bracket cap (2) from rear bracket (3), and then remove rear bush (1) from rear bracket (3), as required.

Reassembly

CAUTION:
- Washing, adjusting and disassembling of shock absorber (clutch plate) are not allowed.
- New oilless bearing have been lubricated when they are supplied as spare parts. DO NOT wash with grease dissolving solvent nor lubricate them with other lubricant.

1. Inspect component parts (Refer to "Starting Motor Inspection:" and replace with new ones as necessary).
2. Apply grease (Refer to "Starting Motor Components:".)
3. Install armature to yoke.
4. Install brushes (1) and brush springs (2) to brush holder (3).




5. Install brush holder (3) to armature while pushing 4 brushes (1) outward.
6. Install rear bush and then rear bracket cap.
7. Install rear bracket (1).




8. Tighten brush holder screws (2).




9. Install over-running clutch assembly (1) to gear shaft (4), using care for installing direction of pinion stop ring (2).




10. Insert shaft assembly (1) into front housing with lever (2) positioned as shown in figure.
11. Install packing (1) so that cuts in packing align with holes for through bolts in front housing.




12. Install plate and seal rubber (4) to front housing.




13. Apply grease to ball (1) and install ball (1) into shaft hole.
14. Install yoke, armature, brush holder and rear bracket to front housing (2) by aligning match marks provided before removal.




15. Tighten through bolts (1).




16. Install magnetic switch assembly (1) and protector (2) (if equipped). Connect wire (switch to motor) to switch terminal.
17. Upon completion of assembly, carry out performance test. Refer to Starting Motor Performance Test:".