Starting System & Charging System (H6DO): Starter: Disassembly

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

Fig 1: Identifying Nut Holding Terminal M Of Magnet Switch Assembly
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Remove the nuts which secure the magnet switch assembly and remove the magnet switch assembly.

Fig 2: Locating Nuts Securing Magnet Switch Assembly
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Remove the starter seal.

Fig 3: Identifying Starter Seal
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Remove the through bolts on both sides, and then remove the starter housing.

Fig 4: Locating Starter Housing Bolts
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Fig 5: Identifying Starter Housing
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Remove the shift lever.

Fig 6: Removing/Installing Shift Lever
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Remove the overrunning clutch, shock absorber bearing and shaft from the yoke as an assembly.

Fig 7: Removing/Installing Overrunning Clutch, Shock Absorber Bearing And Shaft
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Remove the overrunning clutch from shaft assembly as follows:
1. Using a plastic hammer, remove the stopper from snap ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench).
  
  Fig 8: Removing Stopper From Snap Ring
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2. Remove the snap ring (A) from the shaft, and then remove the stopper (B).
  
  Fig 9: Removing/Installing Snap Ring
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3. Remove the overrunning clutch from the shaft.
  
  Fig 10: Removing/Installing Overrunning Clutch
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Remove the shock absorber as follows:
1. Remove the starter plate.
  
  Fig 11: Identifying Starter Plate
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2. Remove the planetary gear.
  
  Fig 12: Identifying Planetary Gear
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3. Remove the snap ring, and then remove the shaft.
  
  Fig 13: Removing/Installing Snap Ring
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  Fig 14: Identifying Shaft Inside Internal Gear
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4. Separate the shock absorber bearing (A) from the Internal gear (B), and then remove the shock absorber (C).
  
  Fig 15: Removing/Installing Shock Absorber Bearing
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Remove the screws to remove the starter cover from the brush holder assembly.
NOTE: Hold the screws down and separate the starter cover so that the brush holder assembly remains on the armature side.

Fig 16: Identifying Starter Cover Screws
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Fig 17: Removing Starter Cover From Brush Holder Assembly
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Remove the brush holder assembly from the armature by hand.
NOTE: Push the brushes against the springs by hand to avoid the damage to the brushes.

Fig 18: Removing/Installing Brush Holder Assembly
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Remove the armature from yoke.

Fig 19: Removing/Installing Armature
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