Overhaul

DISASSEMBLY

1. REMOVE REPAIR SERVICE STARTER KIT




a. Remove the nut and disconnect the lead wire from terminal C.
b. Remove the 2 screws that hold the magnetic switch to the motor terminal 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 assembly together with the starter commutator end frame assembly.




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

3. REMOVE STARTER ARMATURE PLATE




a. Remove the starter armature plate from the starter yoke assembly.

4. REMOVE STARTER COMMUTATOR END FRAME COVER




a. Using a screwdriver, remove the starter commutator end frame cover.

5. REMOVE STARTER ARMATURE ASSEMBLY




a. Using snap ring pliers, remove the snap ring and plate washer.
b. Remove the starter armature assembly from the commutator end frame assembly.

6. REMOVE PLANETARY GEAR




a. Remove the 3 planetary gears from the motor terminal starter kit.

REASSEMBLY

1. INSTALL PLANETARY GEAR




a. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
b. Install the 3 planetary 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 assembly to the starter commutator end frame assembly.




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 with a new one.

3. INSTALL STARTER COMMUTATOR END FRAME COVER




a. Install the starter commutator end frame cover to the starter commutator end frame assembly.

4. INSTALL STARTER ARMATURE PLATE




a. Align the claw of the armature plate with the groove inside the starter yoke assembly, 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 assembly.
b. Install the starter commutator end frame assembly to the starter yoke assembly.

NOTE: The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly 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: 6.0 N.m (61 kgf.cm, 53 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 the 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 terminal C with the nut.

Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)