Section 5 (Starting System & Charging System (H6DO)): Starter: Disassembly

CAUTION: The starter should be placed through a no-load test whenever it has been overhauled.

1. Disconnect the terminal M from the magnet switch assembly.
   Fig 1: Identifying Terminal M

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2. Remove the magnet switch assembly from the starter housing assembly.
   Fig 2: Locating Magnet Switch Assembly Bolts

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3. Remove screws (A) of the brush holder assembly, and through bolts (B) on both sides, and remove the starter cover assembly.
   Fig 3: Identifying Brush Holder Assembly Screws

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4. Remove the brush holder assembly from the armature assembly.
   NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.
   Fig 4: Removing Brush Holder Assembly

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5. Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.
   Fig 5: Locating Armature Assembly And Yoke Assembly

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6. Separate the armature assembly and yoke assembly.
   Fig 6: Separating Armature Assembly And Yoke Assembly

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7. Remove the pinion gear from the internal gear assembly.
   Fig 7: Identifying Pinion Gear

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8. Remove seal rubber (A), plate (B), and seal rubber (C).
   Fig 8: Removing Seal Rubber And Plate

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9. Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one unit.
   Fig 9: Tapping Starter Housing Assembly

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10. Use the following procedures to remove the overrunning clutch from the shaft.
    1. Use an appropriate tool (such as a fit socket wrench), and remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer.
       Fig 10: Tapping Stopper

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    2. Remove snap ring (A) from the shaft, and remove stopper (B).
       Fig 11: Removing Snap Ring

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    3. Remove the overrunning clutch from the shaft.
    Fig 12: Removing Overrunning Clutch

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11. Separate the internal gear assembly and shaft.

Fig 13: Separating Internal Gear Assembly

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