STARTER (for 1.6 kW Type) DISASSEMBLY


  1. REMOVE STARTER TERMINAL


    1. A0119Q5

      Open the terminal cap.

    2. Remove the nut and the starter terminal.

  2. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A0117AK

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

    2. A011BVK

      Remove the 2 nuts that hold the magnet starter switch assembly to the starter housing.

    3. A0117E2E03
      Text in Illustration
      *1 Plunger Hook
      *2 Starter Pinion Drive Lever

      Pull the magnet starter switch assembly while lifting the front part of the magnet starter switch assembly, release the plunger hook from the starter pinion drive lever, and remove the magnet starter switch assembly.

  3. REMOVE STARTER YOKE ASSEMBLY


    1. A011AZI

      Using "TORX" socket wrench T25, remove the 2 through bolts.

    2. A0117Z4

      Pull out the starter yoke together with the commutator end frame.

  4. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01194S

      Remove the 2 screws.

    2. A011A6T

      Pull the starter yoke out of the starter commutator end frame.

      Note

      While holding down the lead wire, remove the starter commutator end frame.

  5. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A0117PI

      Using a screwdriver, pry the end of the spring away from each brush and pull out the 4 brushes from the brush holder so that they are held in place by the springs.

    2. Remove the brush holder.

  6. REMOVE STARTER ARMATURE ASSEMBLY


    1. A011BIT

      Remove the starter armature from the starter yoke.

  7. REMOVE STARTER ARMATURE PLATE


    1. Remove the starter armature plate from the starter drive housing or the starter yoke.

      A011A8CE01
      Text in Illustration
      *1 Starter Drive Housing Assembly *3 Starter Armature Plate
      *2 Starter Yoke Assembly - -

  8. REMOVE STARTER PLANETARY GEAR


    1. A01172V

      Remove the 3 planetary gears from the starter center bearing clutch.

  9. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A011BLP

      Remove the rubber seal from the starter drive housing

    2. A0118VTE01
      Text in Illustration
      *1 Starter Pinion Drive Lever
      *2 Starter Center Bearing Clutch Sub-Assembly

      Remove the starter center bearing clutch with starter pinion drive lever from the starter drive housing.

    3. Remove the starter pinion drive lever from the starter center bearing clutch.