STARTER DISASSEMBLY

PROCEDURE


  1. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A004R2V

      Remove the nut, and then disconnect the field coil wire from terminal C.

    2. A004N8U

      Using a T20 "TORX" socket wrench, remove the 3 screws and magnet starter switch assembly from the starter drive housing.

    3. A004PCWE01
      Text in Illustration
      *1 Plunger
      *2 Pinion Drive Lever
      *3 Return Spring

      Remove the return spring.

    4. Remove the plunger from the pinion drive lever.

  2. REMOVE STARTER YOKE ASSEMBLY


    1. A004U6Q

      Remove the 2 bolts and starter yoke assembly from the starter drive housing.

  3. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A004RGL

      Hold the starter yoke assembly between aluminum plates in a vise.

      Note

      Do not damage the starter yoke assembly.

    2. Remove the 2 screws and starter commutator end frame cover from the starter commutator end frame.

    3. A004TGFE06
      Text in Illustration
      *1 Slotted Washer

      Remove the slotted washer.

    4. A004PD1E04
      Text in Illustration
      *1 Washer
      *2 Starter Commutator End Frame

      Remove the 2 washers.

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

    6. A004T0DE11
      Text in Illustration
      *1 Spring
      *2 Starter Brush Holder Assembly
      *a Rubber Part

      Remove the starter brush holder assembly from the starter armature assembly.

      Note

      Do not pull on the rubber part.

  4. REMOVE STARTER ARMATURE ASSEMBLY


    1. A004PZ7E05
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly

      Remove the starter armature assembly from the starter yoke assembly.

  5. REMOVE STARTER CLUTCH SUB-ASSEMBLY


    1. A004MYQ

      Detach the 3 claws and remove the frame end cover from the plate.

    2. A004UA7

      Detach the 3 claws and remove the plate from the planet carrier.

    3. A004QC4

      Remove the 3 planetary gears from the planet carrier.

    4. A004QJXE03
      Text in Illustration
      *1 Pinion Drive Lever
      *2 Starter Drive Housing Cover
      *3 Starter Drive Housing
      *4 Starter Center Bearing Clutch

      Remove the starter center bearing clutch, pinion drive lever and starter drive housing cover from the starter drive housing.

    5. A004R42E04
      Text in Illustration
      *1 Pinion Stop Collar
      *2 Starter Clutch Sub-assembly

      Using a screwdriver, move the pinion stop collar to the starter clutch sub-assembly.

    6. A004NTYE04
      Text in Illustration
      *1 Pinion Stop Collar
      *2 Snap Ring

      Using a screwdriver, remove the snap ring.

    7. A004R9LE02
      Text in Illustration
      *1 Planet Carrier Shaft Sub-assembly
      *2 Starter Clutch Sub-assembly

      Remove the pinion stop collar and starter clutch sub-assembly from the planet carrier shaft sub-assembly.

  6. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A004TGS

      Using 2 screwdrivers and a hammer, tap off the snap ring from the planet carrier shaft sub-assembly.

    2. Remove the washer from the planet carrier shaft sub-assembly.

    3. A004TQAE04
      Text in Illustration
      *1 Planet Carrier
      *2 Planet Carrier Shaft Sub-assembly

      Remove the planet carrier shaft sub-assembly from the planet carrier.

    4. A004QNDE03
      Text in Illustration
      *1 Damper Rubber
      *2 Planet Carrier
      *3 Intermediate Sealing

      Remove the intermediate sealing and the 3 damper rubbers from the planet carrier.