Disassembling/Assembling Starter

- Remove starter.
- Remove solenoid switch.
- Unscrew dust cap (2).
- Take oft circlip (3), shims (4) and seal (5).

Installation Note:

- Check axial play of armature, correcting with shims if necessary.





- Unscrew housing bolts and take off cover.

Installation Note:

- Align openings for housing bolts and insulator to each other.
- Check bearing sleeve, lubricating with oil before installing.





- Lift springs and pull out carbon brushes.
- Remove holder.

Installation Note:
- Check carbon brushes and commutator for wear, repairing if necessary.





- Remove pole housing.
- Unscrew engaging lever bolt and remove rubber seal.





- Lift out armature with drive pinion and engaging fork.

Installation Note:
- Lubricate guide for engaging fork with grease.
- Check bearing sleeve in drive bearing bracket, lubricating with oil before installing.





- Push back bearing race (1) with a piece of suitable pipe.
- Pry circlip (2) apart and pull it off of the shaft.
- Remove burrs with a file.
- Take off drive pinion (3).

Installation Note:





- Use new circlip (2).
- Lubricate bearing surface for drive pinion with grease.

Installation Note:
- Check pinion for wear (on teeth, bearings, one-way clutch), replacing if necessary.





- Check sleeve in intermediate bearing, replacing if necessary.