Disassembling the starter

Pic. 274. Starter installation drawing 1. Traction relay; 2. Cover; 3. Locking bracket. Spring and rubber washer; 4. Bolt; 5. Collector bearing shield; 6. Starter housing with brush holder; 7. Metal and rubber inserts.; 8. Support pin on the switch lever; 9. Anchor; 10. Power lever; 11. Support ring; 12. Thrust ring; 13. Overrunning clutch with drive gear

Direct Drive Starter

• Disconnect the wires from the traction relay terminals.
• Loosen the bolts and remove the cap (2).
• Unscrew the two relay mounting bolts and remove the traction relay.
• Before further disassembly and if major repairs are planned, the axial play of the armature shaft should be checked. To do this, as shown in Figure 275, insert the probe between the washer and the spring. The gap should be between 0.05 and 0.60 mm. Record the measured gap as it will be needed during assembly.

Pic. 275. Measuring the axial play of the armature shaft before disassembling the starter

• Unscrew the two coupling bolts (4) from the rear side of the starter and remove the drive bearing shield along with the armature from the starter housing.
• Remove the switch lever (unscrew the bolt "8") and pull the armature out of the drive bearing shield. At the same time, note the method of installing the lever in order to subsequently assemble the parts in their original position.
• Remove the back cover.
• Pull the brushes out of the holders and remove the brush holder (14).
• Hit the thrust ring at the end of the armature shaft with a chisel and remove the retaining ring located underneath (Pic. 276). Clean the end of the shaft and remove the gears from the shaft.

Pic. 276. Knocking down the collar ring with a chisel and removing the locking sleeve in the bottom picture.

Starter with gearbox

Pic. 277. Installation drawing of a starter with a gearbox using the example of a 1.6 liter engine. 1. Retaining ring; 2. Gear; 3. Thrust ring; 4. Starter spring; 5. Starter gear housing; 6. Intermediate gear; 7. Reduction gear; 8. Bearing; 9. Freewheel; 10. Pressure spring; 11. Connecting shaft; 12. Steel ball; 13. Spring cup; 14. Bearing stop; 15. O-ring; 16. O-ring; 17. Return spring; 18. Traction relay; 19. Anchor; 20. Rear bearing; 21. Starter housing with stator windings; 22. Brush holder; 23. Cover.

• Unscrew the nut and remove the wire from the traction relay terminal.
• Unscrew the two bolts and pull out the starter housing along with the armature. The 1.4 kW starter has an O-ring.
• Remove the two screws at the end of the starter gear and remove the gear housing with the freewheel, return spring, bearing and reducer idler gear. The 1.4 kW starter has an additional gear.
• There is a small connecting ball on the inside of the connecting shaft. A magnet can be used to remove the ball. Otherwise, the ball can be shaken out.
• Remove the cover attached to two bolts from the other end of the starter. The 1.4 kW starter has an O-ring.
• Use a screwdriver to separate the brush springs from the brushes and remove the brushes from the holders. Disconnect the four brushes and unscrew the brush holder.
• Pull the armature out of the starter housing.