Disassembly and Reassembly

DISASSEMBLY




1. REMOVE DUST PROTECTOR
2. REMOVE FIELD FRAME AND ARMATURE
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
b. Remove the 2 through bolts.
c. Pull out the field frame together with the armature from the magnetic switch.
d. Remove the O-ring from the field frame.




3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Remove the 2 screws.
b. Remove these parts from the magnetic switch:
- Starter housing
- Return spring
- Idler gear
- Bearing
- Starter clutch assembly
c. Remove the 0-ring from the starter housing.




4. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.




5. REMOVE BRUSH HOLDER
a. Remove the 2 screws and end cover from the field frame.




b. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder.

6. REMOVE ARMATURE FROM FIELD FRAME

REASSEMBLY

HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

1. PLACE ARMATURE INTO FIELD FRAME
a. Apply grease to the armature bearings.
b. Insert in armature into the field frame.




2. INSTALL BRUSH HOLDER
a. Place the brush holder on the field frame.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes

NOTE: Check that the positive (+) lead wires are not grounded.

c. Install a new O-ring to the groove of the field frame.




d. Install the end cover to the field frame with the 2 screws.
Torque: 3.8 Nm (39 kg.cm, 34 in.lb)




3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.




4. INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Apply grease to the return spring.
b. Insert the return spring into the magnetic switch hole.




c. Place these parts on the starter housing:
1. New O-ring
2. Starter clutch assembly
3. Idler gear
4. Bearing




d. Install the starter housing to the magnetic switch with the 2 screws.
Torque: 9.3 Nm (95 kg.cm, 82 in.lb)




5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY
a. Install a new O-ring to the groove of the filed frame.
b. Align the protrusion of the field frame with the groove of the magnetic switch, and install the field frame and armature shaft assembly.




c. Install the field frame and armature assembly with the 2 through bolts.
Torque: 9.3 Nm (95 kg.cm, 82 in.lb)
d. Connect the lead wire to terminal C with the nut.
Torque: 5.9 Nm (60 kg.cm, 52 in.lb)

6. INSTALL NEW DUST PROTECTOR