Disassembly and Reassembly

STARTER DISASSEMBLY

Starter Motor / Exploded View:

1 REMOVE DUST PROTECTOR


2 REMOVE FIELD FRAME AND ARMATURE







a. Remove the nut. and disconnect the lead wire from the magnetic switch terminal.

Torque: 5.9 N.m (60 kg.cm, 52 in.lb)

b. Remove the 2 through bolts.

Torque: 5.9 N.m (60 kg.cm, 52 in.lb)







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

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

d. Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.

3 REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR







a. Remove the 2 screws.

Torque: 5.9 N.m (60 kg.cm, 52 in.lb)







b. Remove these parts from the magnetic switch:
1. Starter housing and clutch assembly
2. Return spring
3. Idler gear
4. Bearing







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 frame.

Torque: 1.5 N.m (15 kg.cm, 13 in.lb)

b. Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.







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

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

6. REMOVE ARMATURE FROM FIELD FRAME


STARTER ASSEMBLY
Assembly is in the reverse order of disassembly.