STARTER (for 2.2 kW Type) DISASSEMBLY


  1. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A003I7F

      Remove the nut and disconnect the lead wire from terminal C.

    2. A003CBG

      Using a T25 "TORX" socket wrench, remove the 3 screws holding the magnet starter switch assembly to the starter drive housing.

    3. Remove the magnet starter switch assembly.

    4. Remove the return spring.

    5. A003ID1E01

      Remove the plunger from the pinion drive lever.

  2. REMOVE STARTER YOKE ASSEMBLY


    1. A003AGK

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

    2. Remove the cover ring from the planet carrier.

    3. A003D80

      Remove the plate from the planet carrier.

  3. REMOVE STARTER BRUSH HOLDER ASSEMBLY

    Note

    Do not drop the starter armature assembly.


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

      Note

      Do not damage the starter yoke assembly.

    2. A003E0J

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

    3. Remove the seal ring.

    4. A003DA3E01

      Remove the slotted washer.

    5. A003GC2E01

      Remove the washer.

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

    7. A003B2JE02

      Remove the starter brush holder from the starter armature assembly.

      Note

      Do not pull on the rubber part.

  4. REMOVE STARTER ARMATURE ASSEMBLY


    1. A003EDCE01

      Remove the starter armature from the starter yoke.

  5. REMOVE STARTER CLUTCH SUB-ASSEMBLY


    1. A003FL7

      Remove the 3 planetary gears from the planet carrier.

    2. A003BWKE02

      Remove the starter clutch sub-assembly, pinion drive lever and cover from the starter drive housing.

    3. A003G58E01

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

    4. A003BVLE01

      Using a screwdriver, remove the snap ring.

    5. A003C3Z

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

  6. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A003CI7

      Using 2 screwdrivers and a hammer, tap off the snap ring.

    2. Remove the washer from the planet carrier shaft.

    3. A003F2FE01

      Remove the planet carrier shaft from the planet carrier.

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