Starter Assembly

Loosen the nut which holds terminal M of magnet switch assembly, and then disconnect the harness from terminal.

Fig 1: Identifying Terminal M Of Magnet Switch Assembly
Remove the bolts which hold switch assembly, and then remove the switch assembly, plunger and plunger spring from starter.

Fig 2: Locating Switch Assembly Bolts
Remove the nuts of both sides, and then remove the rear cover.

Fig 3: Locating Rear Cover Nuts
Remove the through-bolts of bolt side, and then detach the end frame and armature from yoke as a unit.

Fig 4: Locating Armature Through-Bolts

Fig 5: Detaching End Frame And Armature From Yoke
Remove the end frame cover.

Fig 6: Identifying End Frame Cover
Remove the snap ring.
Remove the space ring.

Fig 7: Pulling Snap Ring

Fig 8: Identifying Space Ring
Remove the armature from end frame.
Remove the screws.

Fig 9: Locating End Frame Screws
Remove the brush holder assembly from end frame.

Fig 10: Removing Brush Holder Assembly From End Frame
Remove the yoke from front bracket.

Fig 11: Removing Yoke From Front Bracket
Remove the armature plate from the yoke.

Fig 12: Removing Armature Plate From Yoke
Remove the rubber seal and planetary gear.

Fig 13: Identifying Rubber Seal And Planetary Gear
Remove the shaft assembly, overrunning clutch and lever from front bracket as a unit.

Fig 14: Removing Shaft Assembly, Overrunning Clutch And Lever From Front Bracket
Use the following procedures to remove the overrunning clutch from the shaft assembly.
1. Remove the stopper from snap ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).
2. Remove the snap ring, stopper and clutch from shaft.
  
  Fig 15: Tapping Stopper
Remove the snap ring.

Fig 16: Removing Snap Ring
Remove the shock absorber bearing, wave washer and internal gear from shaft.

Fig 17: Removing Shock Absorber Bearing, Wave Washer And Internal Gear From Shaft
Remove the front bearing from front bracket.
1. Set an appropriate tool (ø 13 mm) to front bearing.
2. Using a press, remove the front bearing.
  
  Fig 18: Pressing Front Bearing
Remove the oil less bearing from shock absorber bearing.
1. Set an appropriate tool (ø 20 mm) to oil less bearing.
2. Using a press, remove the oil less bearing.
  
  Fig 19: Pressing Oil Less Bearing
Remove the rear bearing from end frame.
1. Set an appropriate tool (ø 16 mm) to rear bearing.
2. Using a press, remove the rear bearing.
  
  Fig 20: Pressing Rear Bearing