Hitachi Starter, Disassemble and Assemble
Disassemble
Unscrew field winding connection from starter switch.
I Unscrew fastening bolts of starter switch. Then detach starter switch from shift lever and remove from starter.
II Remove torsion spring, plunger and shim from starter switch.
III Unscrew through bolt from starter frame and remove housing cover from starter frame.
IV Remove stator with armature, carbon brush holder and associated O-ring together out of the housing.
Release brush spring with the aid of a suitable assembly tool (wire hooks made by yourself) and pull the carbon brushes out of their brackets.
Important!
Note brush springs!
Remove carbon brush holder from starter frame.
Remove armature shaft with bearings from starter frame.
Unscrew bolts for bearing bracket ring out of shift housing.
Remove bearing bracket ring from shift housing.
Pull freewheel completely out of shift housing.
Carefully lever rubber support out of shift housing using suitable tool, do not damage housing walls and rubber support.
Remove starter lever from housing.
Drive retaining ring (1) back on armature shaft with suitable tool (pipe).
Load return spring via bracket with suitable open-ended wrench. Remove retaining ring with suitable tool.
Remove retaining ring and return spring from pinion gear shaft.
Unscrew pinion shaft from overrunning clutch.
Carefully prise off small ball bearing from the hollow shaft of the freewheel using two screwdrivers.
Press off large ball bearing and hollow shaft from reduction gear using suitable assembly sleeve.
Note spacer washer and spacer ring.
Press off hollow shaft from large ball bearing with suitable assembly sleeve.
Remove large ball bearing on collector side from armature shaft with Remover KM-161-A.
Remove small ball bearing on winding side from armature shaft with remover.
Assemble
Press collector side of ball bearing with suitable mounting sleeve until the stop on the armature shaft.
Closed side of ball bearing faces commutator.
Press in ball bearing on winding side to stop on armature shaft using suitable assembly sleeve.
Closed side of ball bearing faces winding.
Place spacer ring and spacer washer onto hollow shaft of freewheel and press on large ball bearing with suitable mounting sleeve until the stop.
Press reduction gear with spacer ring onto hollow shaft by hand.
Install reduction gear with collar (1) on top.
Press small ball bearing to stop on hollow shaft of overrunning clutch with suitable assembly sleeve.
Lightly coat edge of stator (1) with adhesive sealing compound (black) and place new seal ring onto stator.
Insert armature in starter frame.
Place carbon brush holder on starter frame.
Locking lug (2) must engage in groove on starter frame.
Insert carbon brushes.
Insert springs into guides.
Using screwdriver or other suitable tool, place spring on carbon brush (3).
Place shim on starter switch.
Insert plunger and press torsion spring into corresponding bore holes of starter switch.
Place shift lever in shift housing with groove on top and push on rubber support by hand to stop on both sides.
Before installing starter switch, lightly coat shift housing wall and rear screw contact face (arrows) with adhesive sealing compound (black).
Attach starter switch in starter lever above torsion spring and piston eyelet.
Bolt starter switch to shift housing - 7.5 Nm / 5.5 lbf. ft.
Screw pinion gear shaft into overrunning clutch.
Insert return spring and bracket. Load return spring via bracket with suitable open-ended wrench and lock new retaining ring on shaft.
Inspect
1 Overrunning clutch must block when the starter pinion is turned in the drive direction.
2 Starter pinion must be easy to turn against the drive direction.
Lightly coat reduction gear of freewheel with grease (brown) and insert into housing.
Place bearing bracket ring straight on bearing and press on by hand.
Tighten fastening bolts.
Insert pre-assembled starter motor into shift housing - tightening torque 6.5 Nm / 5 lbf. ft.
Position rear housing cover and tighten through-bolts.
Bolt field windings connection onto starter switch - tightening torque 9 Nm / 6.6 lbf. ft.
After overhauling starter, check starter pinion end play.
Pull out starter pinion by hand and measure distance of pinion to flange.
Connect starter frame to battery negative terminal using auxiliary cable. Using second auxiliary cable, actuate starter switch via terminal 50.
Do not actuate starter switch for longer than 30 seconds.
Measure distance of ejected pinion to flange. Difference between 1st and 2nd measured values must be 0.3 - 1.5 mm.
If the value is not attained or is exceeded, adjust the end play with shims (A). To do this, remove starter again.
Disassemble 
Important! 
Assemble 
Inspect 
