Starting Motor Disassembly

NOTE:

Before disassembling starting motor, be sure to put match marks at 2 locations (A (magnetic clutch (1) and front housing (2)) and B (front housing (2) and yoke (3))) as shown in figure so that any possible mistake can be avoided.
Do not clamp yoke in a vise or strike it with a hammer during repair operations.

Fig 1: Identifying Matchmarks On Starting Motor

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Remove protector (2) (if equipped) and magnetic switch (1).

Fig 2: Removing Protector And Magnetic Switch
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CAUTION: Don't disassemble this switch. If defective, replace as a complete assembly.

Fig 3: Removing Magnetic Switch Spring And Plunger
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Remove bolts (1) shown in the figure, then separate reduction gear assembly (2) from starting motor assembly.

Fig 4: Separating Reduction Gear Assembly From Starting Motor Assembly
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To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).

Fig 5: Removing Packing And Planetary Gears
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Remove seal rubber (1) and plate (2).

Fig 6: Removing Seal Rubber And Plate
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Remove shaft assembly (1) with lever (2).

Fig 7: Removing Shaft Assembly With Lever
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Loosen pinion stop ring (2) fixed by snap ring (1).

Fig 8: Loosening Pinion Stop Ring Fixed By Snap Ring
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Remove snap ring (2), then pull out pinion stop ring (3) and over-running clutch (4) and internal gear (1).
Special tool

(A): 09900-06107

Fig 9: Removing Snap Ring
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Remove rear bracket (1) and brush holder.

Fig 10: Removing Rear Bracket And Brush Holder
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Remove armature (1) from yoke (2) and then ball (3) from the end of armature shaft.

Fig 11: Removing Armature From Yoke
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Remove brush holder (2) from rear bracket (1).

Fig 12: Removing Brush Holder From Rear Bracket
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Remove brush springs (1) and brushes (2).

Fig 13: Removing Brush Springs And Brushes
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Remove rear bracket cap (2) from rear bracket (3), and then remove rear bush (1) from rear bracket (3), as required.

Fig 14: Removing Rear Bracket Cap From Rear Bracket

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