Replacement

1. REPLACE FRONT BEARING

(a) Using SST, remove the bearing. SST 09286-4601 1

(b) Using a press, press in a new rear bearing.

2. REPLACE REAR BEARING

(a) Using SST, remove the bearing. SST 09286-4601 1

(b) Using SST and a press, press in a new bearing. NOTICE:

Be careful of the bearing installation direction.

SST 09820-00030 3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS

(a) Remove the magnetic switch end the cover. Remove the 3 bolts, lead clamp, end cover, gasket and plunger.

(b) Inspect the contact plate for wear.

Using vernier calipers, measure the contact plate for depth of wear.

If the depth of wear is greater than the maximum, replace the contact plate.

P25439

(c) Remove the terminal kit parts.

(1) Using SST, loosen the terminal nuts. SST 09810-38140

Remove the terminal nut, wave washer, terminal insulator (outside), O- ring, terminal bolt, contact plate and terminal insulator (inside).

Remove the terminal nut, wave washer, terminal insulator (outside), O- ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.

(d) Temporarily install these new terminal 30 kit parts.

(1) Insulation paper

(2) Terminal insulator (inside)

(3) Contact plate

(4) Terminal bolt

(6) Terminal insulator (outside)

(7) Wave washer

(8) Terminal nut NOTICE:

Be careful to install the terminal insulators (inside) and wave washer in the correct direction.

(e) Temporarily install these new terminal C kit parts. (1) Terminal insulator (inside) Contact plate Terminal bolt O-ring

Terminal insulator (outside) Wave washer Terminal nut

NOTICE:

Be careful to install the terminal insulators (inside) and wave washer in the correct direction.

(f) Temporarily tighten the terminal nuts.

(g) Tighten the terminal nut.

(1) Put a wood block on the contact plate and press it down with a hand press. Dimensions of wood block: 20 x 37 x 40 mm (0.97 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 Ibf) NOTICE:

• Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 Ibf) of force is applied.

221 Ibf

(psi) = ^ Ram diameter (in.) ^ ^ 3 14 (ft) (kPa) = (kgf/cm2) x 98.1

V06796

• If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.

(2) Using SST, tighten the nut to the specified torque. SST 09810-38140 Torque: 17 Nm (173 kgfcm, 12 ftlbf) NOTICE:

If the nut is over tightened, it may cause cracks on the inside of the insulator.

P25479

(h) Clean the contact surfaces of the contact plate and plunger.

Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.

(i) Reinstall the magnetic switch end cover.

Install the plunger, new gasket, end cover and lead clamp with 3 bolts.

_STARTING - STARTER (Reduction Type)_

ST0J0-02

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