STARTER DISASSEMBLY

PROCEDURE


  1. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A00Y5U0

      Remove the nut and disconnect the lead wire from the magnet starter switch assembly.

    2. A00Y9AP

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

    3. Remove the magnet starter switch assembly.

    4. Remove the return spring.

    5. A00Y6IXC01
      *1 Plunger
      *2 Drive Lever

      Remove the plunger from the drive lever.

  2. REMOVE STARTER YOKE ASSEMBLY


    1. A00Y7EK

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

    2. A00YBD8C01
      *1 Planet Carrier
      *2 Plate

      Remove the plate from the planet carrier.

  3. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A00Y8VH

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

      Note

      Do not overtighten the vise.

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

    3. A00YAKUC01
      *1 Slotted Washer

      Remove the slotted washer.

      Note

      Use caution to prevent the starter armature assembly from dropping.

    4. A00Y6ILC01
      *1 Washer
      *2 Commutator End Frame

      Remove the washer.

      Note

      Use caution to prevent the starter armature assembly from dropping.

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

      Note

      Use caution to prevent the starter armature assembly from dropping.

    6. A00Y77RC01
      *1 Spring
      *2 Rubber
      *3 Brush Holder

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

      Note


      • Do not pull on the rubber.

      • Use caution to prevent the starter armature from dropping.

  4. REMOVE STARTER ARMATURE ASSEMBLY


    1. A00Y8TBC01
      *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. A00Y5YR

      Remove the 3 planetary gears from the planet carrier shaft sub-assembly.

    2. A00YANGC01
      *1 Drive Lever
      *2 Starter Drive Housing Cover
      *3 Starter Drive Housing
      *4 Starter Clutch Sub-assembly
      *5 Planet Carrier

      Remove the starter clutch sub-assembly with planet carrier, drive lever and starter drive housing cover from the starter drive housing.

    3. A00Y9YSC01
      *1 Pinion Stop Collar
      *2 Starter Clutch Sub-assembly

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

    4. A00Y7AYC01
      *1 Snap Ring
      *2 Pinion Stop Collar

      Using a screwdriver, remove the snap ring.

    5. Remove the pinion stop collar.

    6. A00Y6HEC01
      *1 Starter Clutch Sub-assembly
      *2 Planet Carrier Shaft Sub-assembly

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

  6. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A00Y8BN

      Using 2 screwdrivers, remove the snap ring from the planet carrier shaft sub-assembly.

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

    3. A00Y5X6C01
      *1 Planet Carrier
      *2 Planet Carrier Shaft Sub-assembly

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