Bosch Reduction Gear Starter, Disassemble and Assemble
Disassemble
Unbolt field winding connection (1).
Unbolt solenoid switch (3) from drive bearing, pull back and detach.
Remove stator mounting screws (2).
Remove drive bearing.
Lever out sealing plate (1).
Pull out drive lever bearing from guide.
Pull out reduction gear (2) from stator.
Remove plate cap.
Remove armature with collector bearing from stator in direction of arrow. Remove plate cap.
Important!
Do not damage permanent magnets.
Remove protective cap (1) from collector bearing.
Remove collector bearing, retaining washer (1), plain washer and seal ring.
Remove brush holder plate (3).
When re-using: push carbon brushes onto suitable piece of pipe (2) or shaft, to prevent contact springs from springing out.
Remove reduction ring gear (plastic).
Disconnect retaining ring and snap ring - see operation "Bosch Starter, Disassemble and Assemble"
Remove lock washer (1) and washer (2).
Knock permanent magnet (3) carefully from stator. Use soft metal drift.
Assemble
Install permanent magnet, reduction-ring gear, armature, brush holder plate and collector bearing. Insert collector bearing seal ring. Install bearing cap. Install solenoid switch.