Disassembly and Reassembly
DISASSEMBLY1. REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY
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: 5.9 N.m (60 kgf.cm, 52 in.lbf)
c. Pull out the field frame with the armature from the magnetic switch assembly.
d. Remove the O-ring.
NOTE: Align the protrusion of the field frame with the cutout of the magnetic switch.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Remove the 2 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
b. Remove these parts from the magnetic switch assembly:
1. Starter housing
2. Idler gear
3. Bearing
4. Clutch assembly
5. Return spring
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
4. REMOVE BRUSH HOLDER
a. Remove the 2 screws and end cover from the field frame.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
b. Remove the O-ring from the field frame.
HINT: Use a new O-ring.
c. Using a screwdriver, hold the spring tank 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.
5. REMOVE ARMATURE FROM FIELD FRAME
INSPECTION
See Testing and Inspection / Inspection Testing and Inspection
REPLACEMENT
1. INSPECT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or if the bearing sticks, replace the bearing.
2. REPLACE BEARINGS
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new front bearing.
SST 09820-00030
c. Using a press, press in a new rear bearing.
3. REMOVE MAGNETIC SWITCH END COVER
a. 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), packing, O-ring, terminal bolt, contact plate, and terminal insulator (inside).
d. Reinstall terminal kit parts
Install these new parts:
Terminal 30:
1. Terminal insulator (inside)
NOTE: Be careful to install the terminal insulator in the correct direction.
2. Contact plate
3. Terminal bolt
4. O-ring
5. Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Wave washer
7. Terminal nut
e. Install these new parts:
Terminal C:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Terminal insulator (outside)
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nut.
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.
Gauge pressure:
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 (173 kgf.cm, 12 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 with the 3 bolts.
Torque: 2.5 N.m (26 kgf.cm, 23 in.lbf)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
TEST
See Testing and Inspection / Test. Testing and Inspection