STARTER DISASSEMBLY

PROCEDURE

  1. REMOVE MAGNET STARTER SWITCH ASSEMBLY

    1. A165796

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

    2. A165798

      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. A165800C01

      *1

      Plunger

      *2

      Drive Lever

      Remove the plunger from the drive lever.

  2. REMOVE STARTER YOKE ASSEMBLY

    1. A165802

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

    2. A165827C01

      *1

      Planet Carrier

      *2

      Plate

      Remove the plate from the planet carrier.

  3. REMOVE STARTER BRUSH HOLDER ASSEMBLY

    1. A104840

      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. A104841C01

      *1

      Slotted Washer

      Remove the slotted washer.

      Note:

      Use caution to prevent the starter armature assembly from dropping.

    4. A104843C01

      *1

      Washer

      *2

      Starter 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. A104844C01

      *a

      Spring

      *b

      Rubber

      *c

      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. A105361C01

      *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. A165829

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

    2. A165831C01

      *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. A282528C01

      *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. A104905C01

      *1

      Snap Ring

      *2

      Pinion Stop Collar

      Using a screwdriver, remove the snap ring.

    5. Remove the pinion stop collar.

    6. A105365C01

      *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. A105364

      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. A105368C01

      *1

      Planet Carrier

      *2

      Planet Carrier Shaft Sub-assembly

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