Disassembly and Reassembly

DISASSEMBLY




1. REMOVE 2 DUST PROTECTORS
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 kgf.cm, 52 in.lbf)

b. Remove the 2 through bolts.

Torque:
1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)




c. Pull out the field frame together with the armature from the magnetic switch assembly.

NOTE: At the time of notice, please refer to the following items. Align the protrusion of the field frame with the groove of the magnetic switch.

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

HINT: At the time of assembly, please refer to the following items. Use a new O-ring.

3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR




a. 1.4 kW type:
Remove the 2 bolts.

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

b. 2.0 kW type:
Remove the 2 screws.

Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)




c. Remove the starter housing, return spring, idler gear, bearing and starter clutch assembly.

HINT: At the time of assembly, please refer to the following item. Apply grease to the return spring and insert the return spring into the clutch shaft hole.




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

HINT: At the time of assembly, please refer to the following item. Apply grease to the steel ball and insert the steel ball into the clutch shaft hole.

5. REMOVE BRUSH HOLDER




a. Remove the 2 screws w/O-ring and end cover from the field frame.

Torque:
1.4 kW type: 1.5 N.m (15 kgf.cm, 13 in.lbf)
2.0 kW type: 3.8 N.m (39 kgf.cm, 34 in.lbf)

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

HINT: At the time of assembly, please refer to the following item. 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.

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

6. REMOVE ARMATURE FROM FIELD FRAME

INSPECTION




1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
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.




2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is no continuity between the commutator and armature coil core.
If there is continuity, replace the armature.

3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACE
If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe.




4. INSPECT COMMUTATOR CIRCLE RUNOUT
a. Place the commutator on V-blocks.
b. Using a dial indicator 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.










5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
If the diameter is less than minimum, replace the armature.







6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign materials. Smooth out the edge.
If the undercut depth is less than minimum, correct it with a hacksaw blade.




7. INSPECT FIELD COIL FOR OPEN CIRCUIT
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.




8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between the field coil end and field frame.
If there is continuity, repair or replace the field frame.




9. 2.0 kW type:
INSPECT SHUNT COIL FOR OPEN CIRCUIT
Using an ohmmeter, measure the resistance between shunt coil terminals (A) and (B).

Resistance: 1.5 to 1.9 Ohms at 20 °C (68 °F)

If the resistance is not as specified, replace the field frame.










10. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
If the length is less than minimum, replace the brush holder and field frame.










11. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring separates from the brush.
If the installed load is less than minimum, replace the brush springs.




12. INSPECT BRUSH HOLDER INSULATION
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.

13. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or damage.




14. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks.
If necessary, replace the clutch assembly.

15. INSPECT FRONT AND REAR BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.




16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminals 50 and C.
If there is no continuity, check and replace the magnetic switch.




17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between terminal 50 and the switch body.
If there is no continuity, replace the magnetic switch.

REPLACEMENT




1. REPLACE REAR BEARING
a. Using SST, remove the bearing.

SST 09286-46011




b. Using a press, press in a new bearing.




2. REPLACE FRONT BEARING
a. Using SST, remove the bearing.

SST 09286-46011




b. Using SST and a press, press in a new bearing.

NOTE: Be careful of the bearing installation direction.

SST 09820-00031




3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover.
Remove the 3 bolts, end cover, gasket and plunger.




b. Inspect contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.

Maximum wear: 0.9 mm (0.035 in.)

If the depth of wear is greater than the maximum, replace the contact plate.




c. Remove terminal kit parts.
1. Using SST, loosen the terminal nuts.

SST 09810-38140

2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.




d. Install new terminal 30 kit parts.
1. Temporarily install a new terminal insulator (inside).
2. Temporarily install a new contact plate.
3. Temporarily install a new terminal bolt.
4. Temporarily install a new O-ring.
5. Temporarily install a new packing and new terminal insulator (outside).
Install a new packing to a new terminal insulator, and install them.

HINT: Match the protrusion of the insulator with the indentation of the housing.

6. Temporarily install a new wave washer.
7. Temporarily install a new terminal nut.

NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.




e. Install new terminal C kit parts.
1. Temporarily install a new terminal insulator (inside).
2. Temporarily install a new contact plate.
3. Temporarily install a new terminal bolt.
4. Temporarily install a new O-ring.
5. Temporarily install a new terminal insulator (outside).
6. Temporarily install a new wave washer.
7. Temporarily install a new terminal nut.

NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.

f. Temporarily tighten the terminal nuts.




g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.

Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)

Press force:
981 N (100 kgf, 221 lbf)

NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.




- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.




2. Using SST, tighten the nuts to the specified torque.

SST 09810-38140

Torque: 17 N.m (170 kgf.cm, 13 ft.lbf)

NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.





h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.

Torque:
1.4 kW type: 2.5 N.m (25 kgf.cm, 22 in.lbf)
2.0 kW type: 3.6 N.m (37 kgf.cm, 32 in.lbf)

REASSEMBLY

Reassembly is in the reverse order of disassembly.

HINT: At the time of assembly, use high-temperature grease to lubricate the bearing and gears when assembling the starter.