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Outline Outline Removal Components

1. Disconnect Battery Negative (-) Terminal Cable

(1/2)
(1/1) (1/2)
(1/1)

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Removal Components Disassembly Components

2. Remove Starter 1. Remove Magnet Starter Switch Assembly

Magnet starter switch

Drive lever

(1/2)
(1/1) (1/2)
(1/1)

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Disassembly Components Disassembly Components

2. Remove Starter Yoke Assembly 3. Remove Starter Brush Spring

Plate
End cover

Starter housing

Starter yoke

Brush holder insulator

Spring

(1/2)
(1/1) (1/2)
(1/1)

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Disassembly Components Disassembly Components

4. Remove Starter Armature Assembly 5. Remove Starter Clutch Sub-Assembly

Snap ring
Starter armature Starter clutch Stop collar

(1/2)
(1/1) (1/
(1/2)
1)

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Disassembly Remove Magnet Starter Switch Assembly Disassembly Remove Starter Yoke Assembly

1. Disconnect lead wire 2. Remove magnet starter switch assembly 1. Remove starter yoke assembly

Lead wire Magnetic starter switch Drive lever

Starter
housing

Plunger
Starter housing
hook

Starter yoke
Drive lever
End cover

(1/
(1/2)
1) (1/
(1/2)
1)

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Disassembly Remove Starter Brush Spring Disassembly Remove Starter Brush Spring

1. Remove starter brush spring 1. Remove starter brush spring

Plate

Claw

Claw

(1/
(1/2)
2) (1/
(1/2)
2)

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Disassembly Remove Starter Brush Spring Disassembly Remove Starter Brush Spring

1. Remove starter brush spring 1. Remove starter brush spring

Brush holder insulator

Brush Brush spring
Brush spring

(2/
(1/2)
2) (2/
(1/2)
2)

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Disassembly Remove Starter Brush Spring Disassembly Remove Starter Clutch

1. Remove starter brush spring 1. Remove starter clutch

Brush holder
insulator

Cloth Vise

(2/
(1/2)
2) (1/
(1/2)
1)

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Disassembly Remove Starter Clutch Disassembly Remove Starter Clutch

1. Remove starter clutch 1. Remove starter clutch

(1)

Cloth Snap ring

Vise

(1/
(1/2)
1) (1/
(1/2)
1)

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Disassembly Remove Starter Clutch Inspection Components

1. Remove starter clutch

Stop collar

Starter clutch

Armature shaft

(1/
(1/2)
1) (1/2)
(1/1)

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Inspection Inspect Starter Armature Assembly Inspection Inspect Starter Armature Assembly

1. Visual inspection 2. Cleaning

SERVICE HINT:
Visual Check
(1/2)
(1/6) SERVICE HINT: (1/2)
(2/6)
Cleaning /Washing

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Inspection Inspect Starter Armature Assembly Inspection Inspect Starter Armature Assembly

3. Starter armature insulation and continuity check 3. Starter armature insulation and continuity check

Armature coil Armature Commutator Armature Commutator

Armature coil Armature
core core
core

Armature Armature
shaft shaft

No continuity Continuity

(1/2)
(3/6) (1/2)
(3/6)

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Inspection Inspect Starter Armature Assembly Inspection Inspect Starter Armature Assembly

4. Commutator circle runout inspection 5. Inspect outside diameter of commutator

SERVICE HINT: SERVICE HINT:

Shaft Runout Inspection Measuring
(1/2)
(4/6) (1/2)
(5/6)

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Inspection Inspect Starter Armature Assembly Inspection Inspect Field Coil

6. Inspect under cut depth 1. Inspect field coil

Brush lead (Group A)

Armature

Continuity

Lead wire Brush lead

(Group B)

Field coil
Lead wire Starter yoke

Brush lead (Group A)

Brush lead
(Group B) Starter yoke

SERVICE HINT:
Measuring
(1/2)
(6/6) (1/2)
(1/1)

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Inspection Inspect Field Coil Inspection Inspect Brush

1. Inspect field coil 1. Inspect brush

Brush lead (Group A)

Armature
No
continuity

Lead wire

Brush lead
Field coil (Group B)
Starter
yoke
Lead wire

Brush lead (Group A)

Starter yoke
Brush lead (Group B)

SERVICE HINT:
Measuring
(1/2)
(1/1) (1/2)
(1/1)
REFERENCE:
Replace Brush

5
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Inspection Inspect Starter Clutch Sub-Assembly Inspection Inspect Magnet Starter Switch Assembly

1. Inspect starter clutch operation 1. Inspect magnet starter switch operation

Free

Lock

(1/2)
(1/1) (1/2)

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Inspection Inspect Magnet Starter Switch Assembly Inspection Inspect Magnet Starter Switch Assembly

2. Inspect magnet starter switch continuity 2. Inspect magnet starter switch continuity

Terminal 30 Terminal 30
Terminal 50 Terminal 50

Hold-in coil Hold-in coil

Pull-in coil
Switch body Switch body Switch body

Pull-in coil Terminal C Terminal C

Terminal C

Continuity Continuity
Terminal 50 Terminal 50

(1/2)
(2/2) (1/2)
(2/2)

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Reassembly Components Reassembly Components

1. Install Starter Clutch Sub-Assembly 2. Install Starter Armature Assembly

Snap ring
Starter clutch Stop collar Starter armature assembly

(1/2)
(1/1) (1/2)
(1/1)

6
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Reassembly Components Reassembly Components

3. Install Starter Brush Spring 4. Install Starter Yoke Assembly

Plate
End cover

Starter housing

Starter yoke

Brush holder insulator

Spring

(1/2)
(1/1) (1/2)
(1/1)

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Reassembly Components Reassembly Install Starter Clutch Sub-Assembly

5.Install Magnet Starter Switch Assembly 1. Install starter clutch sub-assembly

Magnet starter switch

Drive lever
Grease

(1/2)
(1/1) (1/2)

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Reassembly Install Starter Clutch Sub-Assembly Reassembly Install Starter Clutch Sub-Assembly

1. Install starter clutch sub-assembly 1. Install starter clutch sub-assembly

Stop collar

Starter clutch

(1/2) (1/2)

7
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Reassembly Install Starter Clutch Sub-Assembly Reassembly Install Starter Clutch Sub-Assembly

1. Install starter clutch sub-assembly 1. Install starter clutch sub-assembly

Snap Stop
ring collar

Stop collar

Starter clutch
Snap ring

Stop collar

SERVICE HINT:
Snap Ring
(1/2) (1/2)
(2/2)

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Reassembly Install Starter Brush Spring Reassembly Install Starter Brush Spring

1. Install starter armature assembly on starter yoke 2. Install starter brush spring 2. Install starter brush spring

Brush holder insulator

Aluminium
plate

Vise

(1/2)
(1/1) (1/2)
(1/1)

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Reassembly Install Starter Brush Spring Reassembly Install Starter Brush Spring

2. Install starter brush spring 2. Install starter brush spring

Brush holder insulator

Brush spring
Brush Brush
spring

Brush holder insulator

Brush spring

Brush holder insulator

(1/2)
(1/1) (1/2)
(1/1)

8
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Reassembly Install Starter Brush Spring Reassembly Install Starter Yoke Assembly

2. Install starter brush spring 1. Install starter yoke assembly

Drive lever
Plate

Grease

Claw

Claw Starter housing

Starter yoke
End cover

(1/2)
(1/1) (1/2)
(1/1)

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Reassembly Install Magnet Starter Switch Assembly Test Components

1. Install magnet starter switch 2.Connect lead wire

Pull-in test

Magnet starter switch

Starter housing
Lead wire

Plunger hook

Drive lever

(1/2)
(1/1) (1/2)
(1/1)

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Test Components Test Components

Hold-in test Check pinion gear clearance

(1/2)
(1/1) (1/2)
(1/1)

9
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Test Components Test Pull-In Test

1. Pull-in test

No-load test

Starter body Terminal 30 Pinion gear

Terminal 50 Test lead A
(1/2)
(1/1) Terminal C Hold-in coil (1/2)
(1/1)

Field coil lead wire Pull-in coil

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Test Hold-In Test Test Check Pinion Gear Clearance

1. Hold-in test 1. Check pinion gear clearance

Starter body Terminal 30 Pinion gear

SERVICE HINT:
Terminal 50 Test lead A Measuring
Terminal C Hold-in coil (1/2)
(1/1) (1/2)
(1/1)

Field coil lead wire Pull-in coil

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Test Pinion Return Test Test No-Load Test

1. Pinion return test 1. No-load test

Starter body Terminal 30 Pinion gear Starter body

Terminal 50 Test lead A Terminal 50
Terminal C Hold-in coil (1/2)
(1/1) Terminal C (1/2)

Field coil lead wire Pull-in coil Terminal 30

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Test No-Load Test Installation Components

1. No-load test 1. Install Starter

Starter body

Terminal 30

Terminal C

Terminal 50

(1/2)
(2/2) (1/2)
(1/1)

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Installation Components Installation Final inspection

2. Connect Battery Negative (-) Terminal Cable

Ignition switch

Starter

(1/2)
(1/1) (1/2)
(1/1)

11