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STARTER DISASSEMBLY

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  1. Click here

    REMOVE MAGNET STARTER SWITCH ASSEMBLY


    1. A01IOHU

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

    2. A01ITYH

      Using a T20 "TORX" socket wrench, remove the 3 screws and magnet starter switch assembly from the starter drive housing.

    3. A01IO1BE01

      Remove the return spring.

      Table 1. Text in Illustration
      *1 Plunger
      *2 Pinion Drive Lever
      *3 Return Spring

    4. Remove the plunger from the pinion drive lever.

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    REMOVE STARTER YOKE ASSEMBLY


    1. A01IS7T

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

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    REMOVE STARTER BRUSH HOLDER ASSEMBLY


    1. A01IR8G

      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. A01ITSRE04

      Remove the slotted washer.

      Table 2. Text in Illustration
      *1 Slotted Washer
    4. A01IT5TE04

      Remove the 2 washers.

      Table 3. Text in Illustration
      *1 Washer
      *2 Starter Commutator End Frame

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

    6. A01IQD8E07

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

      Table 4. Text in Illustration
      *1 Spring
      *2 Starter Brush Holder Assembly
      *a Rubber Part
      Note:

      Do not pull on the rubber part.

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    REMOVE STARTER ARMATURE ASSEMBLY


    1. A01ITB0E05

      Remove the starter armature assembly from the starter yoke assembly.

      Table 5. Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly
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    REMOVE STARTER CLUTCH SUB-ASSEMBLY


    1. A01INTL

      Detach the 3 claws and remove the frame end cover from the plate.

    2. A01IOW9

      Detach the 3 claws and remove the plate from the planet carrier.

    3. A01ITEF

      Remove the 3 planetary gears from the planet carrier.

    4. A01IP3ME01

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

      Table 6. Text in Illustration
      *1 Pinion Drive Lever
      *2 Starter Drive Housing Cover
      *3 Starter Drive Housing
      *4 Starter Center Bearing Clutch
    5. A01IO8DE04

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

      Table 7. Text in Illustration
      *1 Pinion Stop Collar
      *2 Starter Clutch Sub-assembly
    6. A01IT37E04

      Using a screwdriver, remove the snap ring.

      Table 8. Text in Illustration
      *1 Pinion Stop Collar
      *2 Snap Ring
    7. A01IN33E01

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

      Table 9. Text in Illustration
      *1 Planet Carrier Shaft Sub-assembly
      *2 Starter Clutch Sub-assembly
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    REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A01IUEC

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

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

    3. A01IOXWE04

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

      Table 10. Text in Illustration
      *1 Planet Carrier
      *2 Planet Carrier Shaft Sub-assembly
    4. A01IURSE01

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

      Table 11. Text in Illustration
      *1 Damper Rubber
      *2 Planet Carrier
      *3 Intermediate Sealing