Starting/Charging Systems (H6DO): Starter: Disassembly

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

Fig 1: Identifying Terminal M
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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
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Remove the nuts of both sides, and then remove the rear cover.

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

Fig 4: Locating Through-Bolts Of Bolt Side
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Fig 5: Identifying Yoke, Armature And End Frame
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Remove the end frame cover.

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

Fig 7: Identifying Space Ring
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Fig 8: Identifying Space Ring And Space Ring
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Remove the armature from end frame.
Remove the screws.

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

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

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

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

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

Fig 14: Identifying Shaft Assembly, Clutch And Lever
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Remove the overrunning clutch from shaft assembly as follows:
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: Identifying Snap Ring, Stopper And Clutch From Shaft
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Remove the snap ring.

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

Fig 17: Identifying Shock Absorber Bearing, Wave Washer And Internal Gear
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Remove the front bearing from front bracket.
1. Set an appropriate tool (diameter 13 mm) to front bearing.
2. Using a press, remove the front bearing.
Fig 18: Identifying Front Bearing
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Remove the oilless bearing from shock absorber bearing.
1. Set an appropriate tool (diameter 20 mm) to oilless bearing.
2. Using a press, remove the oilless bearing.
Fig 19: Identifying Oilless Bearing
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Remove the rear bearing from end frame.
1. Set an appropriate tool (diameter 16 mm) to rear bearing.
2. Using a press, remove the rear bearing.
Fig 20: Removing Rear Bearing
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