Disassembly
1. Remove the traction relay.
A) Loosen the nut and disconnect the wiring harness! from the output of the traction relay.
b) Loosen the 2 nuts securing the traction relay to the starter cover from the gear side and remove the relay.
2. Loosen the two tie bolts and pull out the housing assembly with the stator winding together with the armature.
3. Loosen the two O-ring screws and remove the manifold side cover while holding the wiring harness.
4. Remove the brush holder.
A) Use a screwdriver to depress the spring and disconnect the brush holder.
b) Disconnect 4 brushes and remove the brush holder.
5. Disconnect the anchor from the starter housing.
6. Remove 2 O-rings from starter housing.
7. Disconnect the drive arm and freewheel with drive gear together with the shock absorber from the cover on the side of the drive gear.
8. Remove satellites.
Disconnect the washer from the shock absorber (1), 3 satellites (2) and plate (3).
9. Remove freewheel from drive gear.
A) Using a screwdriver, slide the stop sleeve towards the freewheel.
b) Remove the retaining ring with a screwdriver.
V) Remove the limiter sleeve and freewheel.
10. Remove carrier and epicycle.
A) Using pliers, remove the circlip and washer.
b) Remove the carrier and washer.
Assembly
Note: Use high temperature grease on bearings and starter gear assembly.
Install epicycle and carrier.
A) Apply grease to the epicycle at the points of contact with the shock absorber and satellites.
b) Align the groove on the epicycle with the tab inside the shock absorber.
V) Insert and rotate the epicycle to secure the shock absorber.
G) Apply high quality grease with additives to the bearing.
d) Lubricate the washer and install it on the carrier.
e) Install the carrier in the shock absorber.
and) Install the washer and circlip using pliers.
2. Install the traction relay.
A) Apply grease to the bushing and into the freewheel stop bushing groove v.
b) Install the freewheel and stop sleeve to the carrier.
V) Lubricate the retaining ring and install it in the carrier groove.
G) Use a vise to crimp the circlip.
d) While holding the freewheel, seat the carrier and install the stopper sleeve onto the retaining ring using a plastic-faced hammer.
3. Install the satellites.
A) Lubricate the pinion gears and carrier flange with guides.
b) Install washer and 3 satellites.
V) Install the plate, aligning its hole with the protrusion inside the shock absorber.
4. Install the drive arm and overrunning clutch with shock absorber.
A) Apply a high quality grease with additives to the bearing in the drive side cover.
b) Apply grease to the drive arm at the fulcrum,
V) Install the drive lever to the freewheel.
G) Align the tab on the shock absorber with the groove on the cover on the drive side.
5. Install new O-rings on the starter housing.
6. Install the anchor in the starter housing.
7. Install the brush holder.
A) Install the brush holder on the armature to the appropriate position.
b) Using a screwdriver, depress the brush spring and connect the brush to the brush holder. Install 4 brushes in this way.
Note: check that the wires (+) brushes are not in contact with "weight".
8. Install manifold.
A) Apply turbine oil with additives to the bearing in the cover on the manifold side.
b) Install the cover using 2 new O-ring screws.
9. Install starter housing and anchor assembly.
A) Align the groove in the starter housing with the bump on the shock absorber.
b) Install the starter housing with anchor assembly and secure it with 2 bolts.
10. Install the traction relay.
A) Install the cover on the traction relay.
b) Install the traction relay and secure it with 2 nuts.
V) Connect the wiring to starter terminal C and tighten the nut.