Disassembly and Reassembly

CLEANING STARTER MOTOR PARTS
1. Do not immerse parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

REPLACEMENT OF BRUSHES AND SPRINGS




1. Brushes that are worn beyond wear limit line, or oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with pliers, taking care not to damage pigtail




3. Sand pigtail end with sandpaper to ensure good soldering.
4. Insert pigtail into hole provided in new brush and solder it. Make sure that pigtail and excess solder do not come out onto brush surface.
5. When replacing ground brush, slide the brush from brush holder by prying retaining spring back.

REMOVAL OF SNAP RING AND STOP RING




1. Press the stop ring to the snap ring side using a socket wrench.




2. After removing the snap ring (using snap-ring pliers), remove the stop ring and the overrunning clutch.

REASSEMBLY OF THE STOP RING AND SNAP RING




Using a suitable pulling tool, pull overrunning clutch stop ring over snap ring.

CHECKING PINION END GAP CLEARANCE

Fig. 4 Pinion Gap Adjustment (Part 1 Of 3):

1. Disconnect the field coil wire from the M-terminal of the solenoid.
2. Connect a 12V battery the S-terminal and the M-terminal.
3. The pinion will move out.

CAUTION: This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.

Fig. 4 Pinion Gap Adjustment (Part 2 Of 3):

4. Check the pinion to stopper clearance (pinion gap) with a feeler gauge.
Pinion gap : 0.5 - 2.0 mm (0.02 - 0.079 in.)




5. If the pinion gap is out of specification, adjust by adding or removing gaskets between the solenoid and the front bracket.