Disassembly and Reassembly

OVERHAUL




1. REMOVE STARTER YOKE ASSEMBLY
a. Remove the starter cover.
b. Remove the nut, and disconnect the lead wire from the C terminal.
c. Remove the 2 through bolts. Pull out the field frame together with the armature.
d. Remove the O-ring from the field frame.

2. REMOVE MAGNET STARTER SWITCH ASSEMBLY




a. Remove the 2 screws. Remove the starter housing and clutch assembly.




b. Remove these parts from the Starter housing.
1. Starter magnet switch return spring
2. Starter idle gear pinion
3. Starter idle gear retainer
4. starter idle gear clutch roller




c. Using a magnetic finger, remove the steel ball from the clutch shaft hole.




3. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY
a. Remove the 2 screws and end cover from the field frame.
b. Remove the O-ring from the field frame.




4. REMOVE STARTER BRUSH HOLDER ASSEMBLY
a. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.

5. REMOVE STARTER ARMATURE ASSEMBLY
6. INSPECT STARTER ARMATURE ASSEMBLY




a. Using an ohmmeter, check that there is continuity between the segments of the commutator.
If there is no continuity between any segment, replace the armature.




b. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.




c. Place the commutator on V-blocks. Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.




d. Using vernier calipers, measure the commutator diameter.
Standard diameter: 30 mm (1.18 in.)
Minimum diameter: 29 mm (1.14 in.)
If the diameter is less than minimum, replace the armature.




e. Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a hacksaw blade.

7. INSPECT FIELD COIL




a. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead.
If there is no continuity, replace the field frame.




b. Using an ohmmeter, check that there is no continuity between the field coil brush lead and field frame.
If there is continuity, repair or replace the field frame.




8. INSPECT BRUSH
a. Using vernier calipers, measure the brush length.
Standard length: 15.5 mm (0.61 in.)
Minimum length: 8.5 mm (0.335 in.)
If the length is less than minimum, replace the brush holder and field frame.




9. INSPECT STARTER BRUSH HOLDER ASSEMBLY
a. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.

10. INSPECT MAGNET STARTER SWITCH ASSEMBLY




a. Using an ohmmeter, check that there is continuity between terminals 50 and C
If there is no continuity, check and replace the magnetic switch.




b. Using an ohmmeter, check that there is continuity between terminals 50 and the switch body.
If there is no continuity, replace the magnetic switch.




11. INSPECT STARTER CLUTCH SUB-ASSEMBLY
a. Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage.
b. Hold the starter clutch and rotate the pinion gear counter- clockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks.
If necessary, replace the clutch assembly.

12. REMOVE STARTER CLUTCH SUB-ASSEMBLY




a. Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar.




b. Push down the pinion gear.
c. Using a plastic faced hammer, tap down the stop collar.




d. Using a screwdriver, pry out the snap ring.




e. Remove the stop collar.
f. Remove the pinion gear.
g. Remove the compression spring.




h. Push down the starter housing, and remove the spring retainer.
i. Disassemble the starter housing.
j. Disassemble the starter clutch.
k. Disassemble the clutch shaft.
l. Disassemble the compression spring.

13. INSTALL STARTER CLUTCH SUB-ASSEMBLY




a. Assemble the starter housing.
b. Assemble the starter clutch.
c. Assemble the compression spring.
d. Assemble the clutch shaft.




e. Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar.




f. Push down the starter housing, and install the spring retainer, compression spring, pinion gear and stop collar.




g. Push down the pinion rear.
h. Using snap ring pliers, install a new snap ring.




i. Put a screwdriver in under the stop collar as shown in the illustration.
j. Tap the clutch shaft with plastic faced hammer to install the snap ring onto the stop collar.

14. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply grease to the bearings, and install it to the field frame.

15. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY




a. Install a O-ring to the groove of the field frame.
b. Install the end frame with the 2 screws.

Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)

16. INSTALL MAGNET STARTER SWITCH ASSEMBLY
a. Apply grease to the steel ball, and install it to the clutch shaft hole.




b. Apply grease to the these parts, and its to the Starter housing.
1. Starter magnet switch return spring
2. Starter idle gear pinion
3. Starter idle gear retainer
4. starter idle gear clutch roller

c. Apply grease to the clutch gear.
d. Install the starter housing and clutch assembly with the 2 screws.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)

17. INSTALL STARTER YOKE ASSEMBLY
a. Install a O-ring to the groove of the field frame.




b. Pull out the field frame together with the armature.

HINT: Align the protrusion of the field frame with the groove of the magnetic switch.

c. Install the field frame and armature assembly with the 2 through bolts.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)

d. Connect the lead wire to the C terminal with the nut.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)