Starting Motor Disassembly And Assembly: Disassembly

NOTE: Do not clamp yoke in a vise or strike it with a hammer during repair operations.

Disconnect lead wire (1) from terminal "M" (2).

Fig 1: Identifying Lead Wire & Terminal M
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Loosen screws (1) and then remove protector (2).

Fig 2: Identifying Protector
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Put match marks at 2 locations (A (magnetic switch (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.

Fig 3: Identifying Magnetic Switch, Front Housing & Yoke
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Loosen screws (4) and then remove magnetic switch (1), spring (2) and plunger (3).
CAUTION: Don't disassemble magnetic switch. If defective, replace as a complete assembly.

Fig 4: Identifying Magnetic Switch, Spring & Plunger
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Remove through bolts (1) shown in the figure, then separate reduction gear assembly (2) from starting motor assembly.

Fig 5: Identifying Reduction Gear Assembly
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To overhaul reduction gear assembly, remove packing (2) and planetary gears (1).

Fig 6: Identifying Packing & Planetary Gears
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Remove seal rubber (1) and plate (2).

Fig 7: Identifying Seal Rubber & Plate
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Remove shaft assembly (1) with lever (2).

Fig 8: Identifying Shaft Assembly & Lever
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Loosen pinion stop ring (2) fixed by snap ring (1).

Fig 9: Locating Pinion Stop 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
1. 09900-06107
Fig 10: Identifying Snap Ring, Pinion Stop Ring, Over-Running Clutch & Internal Gear
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Remove rear bracket (1) and brush holder.

Fig 11: Identifying Rear Bracket, Armature & Yoke
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Remove armature (1) from yoke (2).

Fig 12: Identifying Armature & Yoke
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Remove brush holder (2) from rear bracket (1).

Fig 13: Identifying Brush Holder & Rear Bracket
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Remove brush springs (1) and brushes (2).

Fig 14: Identifying Brush Springs & Brushes
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