STARTER(for 2.0 kW Type) DISASSEMBLY

PROCEDURE


  1. REMOVE STARTER TERMINAL


    1. A005MIK

      Open the terminal cap.

    2. Remove the nut and starter terminal.

  2. REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A005JZX

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

    2. A005I2Q

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

    3. A005MD1E03
      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. A005ISC

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

    2. A005L5G

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

  4. REMOVE STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A005JQ5

      Remove the 2 screws.

    2. A005JT8

      Pull the starter commutator end frame assembly.

      Note

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

  5. REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A005IFC

      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 starter brush holder assembly.

  6. REMOVE STARTER ARMATURE ASSEMBLY


    1. A005HUJ

      Remove the starter armature assembly from the starter yoke assembly.

  7. REMOVE STARTER ARMATURE PLATE


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

      A005J4NE04
      Text in Illustration
      *1 Starter Drive Housing Assembly *2 Starter Yoke Assembly
      *3 Starter Armature Plate - -

  8. REMOVE PLANETARY GEAR


    1. A005GKH

      Remove the 3 planetary gears from the starter center bearing clutch sub-assembly.

  9. REMOVE STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A005J0G

      Remove the rubber seal from the starter drive housing.

    2. A005JTPE01
      Text in Illustration
      *1 Starter Pinion Drive Lever
      *2 Starter Center Bearing Clutch Sub-assembly

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

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

  10. REMOVE DUST STARTER PROTECTOR


    1. A005LR2

      Remove the dust starter protector from the starter yoke assembly.