Overhaul

DISASSEMBLY




1. REMOVE REPAIR SERVICE STARTER KIT
a. Remove the nut and disconnect the lead wire from the repair service starter kit.




b. Remove the 2 screws which are used to secure the repair service starter kit to the repair service starter kit.
c. Remove the repair service starter kit.
d. Remove the return spring and the plunger from the repair service starter kit.




2. REMOVE STARTER YOKE ASSEMBLY
a. Remove the 2 through bolts and pull out the starter yoke together with the starter commutator end frame.




b. Remove the starter yoke from the starter commutator end frame.




3. REMOVE STARTER ARMATURE PLATE
a. Remove the starter armature plate from the starter yoke.




4. REMOVE DRIVE HOUSING STARTER BEARING COVER
a. Using a screwdriver, remove the drive housing starter bearing cover.




5. REMOVE STARTER ARMATURE ASSEMBLY
a. Using snap ring pliers, remove the snap ring and the plate washer.
b. Remove the starter armature from the commutator end frame.




6. REMOVE PLANET GEAR
a. Remove the 3 planet gears from the motor terminal starter kit.

REASSEMBLY




1. INSTALL PLANET GEAR
a. Apply high-temperature grease to the planet gears and pin parts of the planetary shaft.
b. Install the 3 planet gears to the motor terminal starter kit.




2. INSTALL STARTER ARMATURE ASSEMBLY
a. Apply high-temperature grease to the plate washer and the armature shaft.
b. Install the starter armature to the starter commutator end frame.
c. Using snap ring pliers, install the plate washer and a new snap ring.




d. Using vernier calipers, measure the snap ring.

Maximum length: 5.0 mm (0.197 in.)

If the length is greater than the maximum, replace the snap ring.




3. INSTALL DRIVE HOUSING STARTER BEARING COVER
a. Install the drive housing starter bearing cover to the starter commutator end frame.




4. INSTALL STARTER ARMATURE PLATE
a. Align the claw of the armature plate with the groove inside the starter yoke, and install the starter armature plate.




5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
a. Align the starter commutator end frame rubber with the groove of the starter yoke.
b. Install the starter commutator end frame to the starter yoke.

NOTE: The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet to break.




6. INSTALL STARTER YOKE ASSEMBLY
a. Align the claw of the starter yoke with the groove inside the motor terminal starter kit.




b. Install the starter yoke with the 2 through bolts.

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




7. INSTALL REPAIR SERVICE STARTER KIT
a. Apply high-temperature grease to the plunger and the hook.
b. Hang the plunger hook of the repair service starter kit to the drive lever hook.
c. Install the plunger and the return spring.




d. Install repair service starter kit with the 2 screws.

Torque: 7.5 N.m (76 kgf.cm, 66 in.lbf)




e. Connect the lead wire to the repair service starter kit with the nut.

Torque: 9.8 N.m (100 kgf.cm, 87 in.lbf)