STARTER (for 1.7 kW Type) DISASSEMBLY


  1. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A003CDR

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

    2. A003IBZ

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

    3. Remove the magnet starter switch.

    4. Remove the return spring.

    5. A003BHEE02
      Text in Illustration
      *1 Plunger
      *2 Pinion Drive Lever

      Remove the plunger from the pinion drive lever.

  2. REMOVE STARTER YOKE ASSEMBLY


    1. A003HUR

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

    2. A003EGZ

      Remove the plate from the planet carrier.

  3. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A003BGX

      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. A003AJDE03
      Text in Illustration
      *1 Slotted Washer

      Remove the slotted washer.

    4. A003FSGE03
      Text in Illustration
      *1 Washer
      *2 Commutator End Frame

      Remove the washer.

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

    6. A003CD4E04
      Text in Illustration
      *1 Rubber Part
      *2 Brush Holder
      *3 Spring

      Remove the starter brush holder from the starter armature.

      Note

      Do not pull on the rubber part.

  4. REMOVE STARTER ARMATURE ASSEMBLY


    1. A003ELVE03
      Text in Illustration
      *1 Starter Yoke
      *2 Starter Armature

      Remove the starter armature from the starter yoke.

  5. REMOVE STARTER CLUTCH SUB-ASSEMBLY


    1. A003EJE

      Remove the 3 planetary gears from the planet carrier.

    2. A003AKSE03
      Text in Illustration
      *1 Pinion Drive Lever
      *2 Cover
      *3 Starter Drive Housing
      *4 Starter Center Bearing Clutch

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

    3. A003EULE03
      Text in Illustration
      *1 Collar
      *2 Clutch

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

    4. A003DTWE03
      Text in Illustration
      *1 Snap Ring
      *2 Collar

      Using a screwdriver, remove the snap ring.

    5. A003AZF

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

  6. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A003HSH

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

    2. Remove the washer from the planet carrier shaft.

    3. A003HBHE03
      Text in Illustration
      *1 Planet Carrier
      *2 Planet Carrier Shaft

      Remove the planet carrier shaft from the planet carrier.

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