Disassembly and Assembly

UNIT REPAIR

DISASSEMBLY






NOTE:
- Before disassembling starting motor, be sure to put match marks at two locations (A & B) 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 magnetic switch.






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




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




3. To overhaul reduction gear assembly, remove packing and planetary gear.




4. Remove seal rubber and plate.




5. Remove shaft assembly with lever.




6. Loosen pinion stop ring fixed by snap ring.




7. Remove snap ring, then pull out pinion stop ring and overrunning clutch and internal gear.

Special Tool
(A): 09900-06107




8. Remove rear bracket and brush holder.




9. Remove armature from yoke.




10. Remove brush holder from rear bracket.




11. Remove brush spring and brush.




12. Remove rear bracket cap, and then remove rear brush as required.

ASSEMBLY

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

1. Inspect component parts (Refer to INSPECTION) and replace with new ones as necessary.
2. Apply grease (Refer to STARTING MOTOR of GENERAL DESCRIPTION).




3. Install armature to yoke.
4. Install brushes and brush springs to brush holder.
5. Install brush holder to armature while pushing 4 brushes outward.




6. Install rear bush and then rear bracket cap.
7. Install rear bracket.
7. Tighten brush holder screws.




9. Install over-running clutch assembly to planetary carrier shaft, using care for installing direction of pinion stop ring.




10. Insert shaft ass'y into front housing with lever positioned as shown in figure.




11. Install packing so that cuts in packing align with holes for through bolt in front housing.
12. Install plate and seal rubber to front housing.




13. Apply grease to ball and install ball into shaft hole.




14. Install yoke, armature, brush holder and rear bracket to front housing by aligning match marks provided before removal.
15. Tighten housing bolts.




16. Install magnetic switch assembly and connect wire (switch to motor) to switch terminal.
17. Upon completion of assembly, carry out PERFORMANCE TEST. Testing and Inspection