The starter is located on the firewall side of the engine block, adjacent to the flywheel or torque converter housing. On 1170cc and 1237cc models, use a direct drive type starter, while the CVCC uses a gear reduction starter. Otherwise, the two units are similar in operation and service. Both starters are 4-pole, series wound, DC units to which an outboard solenoid is mounted. When the ignition switch is turned to the start position, the solenoid armature is drawn in, engaging the starter pinion with the flywheel. When the starter pinion and flywheel are fully engaged, the solenoid armature closes the main contacts for the starter, causing the starter to crank the engine. When the engine starts, the increased speed of the flywheel causes the gear to overrun the starter clutch and rotor. The gear continues in full mesh until the ignition is switched from the start to the on position, interrupting the starter current. The shift lever spring then returns the gear to its neutral position.
REMOVAL & INSTALLATION
See Figures 1 and 2
- Disconnect the negative battery terminal and the starter motor cable at the positive terminal.
- Disconnect the starter motor cable from the motor.
- Remove the starter motor by loosening the two attaching bolts. On CVCC models, the bolts attach from opposing ends of the starter.
- To install, reverse the removal procedures. Torque the starter-to-engine bolts to 29-36 ft. lbs. and make sure that all wires are securely connected.
STARTER DRIVE REPLACEMENT
Hitachi And Nippondenso Direct Drive Types
See Figures 3, 4 and 5
- Remove the solenoid by loosening and removing the attaching bolts.
- Remove the two brush holder plate retaining screws from the rear cover. Also pry off the rear dust cover along with the clip and thrust washer(s).
- Remove the two through-bolts from the rear cover and lightly tap the rear cover with a mallet to remove it.
- Remove the four carbon brushes from the brush holder and the brush holder.
- Separate the yoke from the case. The yoke is provided with a hole for positioning, into which the gear case lock pin is inserted.
- Pull the yoke assembly from the gear case, being sure to carefully detach the shift lever from the pinion.
- Remove the armature unit from the yoke casing and the field coil.
- To remove the pinion gear from the armature, first set the armature on end with the pinion end facing upward and pull the clutch stop collar downward toward the pinion. Remove the pinion stop clip, then, pull the pinion stop and gears from the armature shaft as a unit.
- To assemble and install the starter motor, reverse the disassembly and removal procedures. Be sure to install new clips, be careful of the installation direction of the shift lever.
These starters come in 1.0 and 1.4 KW sizes and are used on various models, the larger power rating on the larger engines. They may be identified in two ways. This starter uses a double reduction set of pinion gears and has a very wide reduction gear housing. Also, its solenoid is housed entirely within the housing of the starter, rather than in an externally visible unit.
- Remove the solenoid end cover. Pull out the solenoid. There is a spring on the shaft and a steel ball at the end of the shaft.
- Remove the through bolts retaining the end frame to the motor and solenoid housing.
- Remove the end frame. The over-running clutch assembly complete with drive gear can be removed. The idler and motor pinion gears can be removed separately. The idler gear retains five steel roller bearings.
- The clutch assembly is held together by a circlip. Push down on the gear against the spring inside the clutch assembly and remove the circlip with a circlip expander. Slide the stopper ring, gear, spring and washer out of the clutch assembly.
- To assemble, reverse the disassembly procedures. The stopper ring is installed with the smaller end with the lip towards the clutch. Be sure that the steel ball is in place at the end of the solenoid shaft. Grease all sliding surfaces of the solenoid before reassembly.