Isuzu AA-6HK1T, Workshop Manual

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STARTING AND CHARGING 6D3–15
1. Place matching marks on the magnetic switch and
yoke to ensure reassembly to their original positions.
2. Connect the starter motor to a battery. The pinion
rises and begins to rotate.
3. Open switch-2 to stop pinion rotation.
4. Separate the stop ring by striking it with a pipe and
bar.
5. Remove the stop ring, the snap ring, the pinion, and
the pinion spring.
6. Discard the stop ring.
NOTE: Pinion removal should require no more than 10
seconds. If more time is required, heat from the
armature will cause the starter damage.
Legend
(1) Pinion
(2) Clutch shaft
(3) Snap ring
(4) Stop ring
(5) Pipe
(6) Pinion spring
7. Remove the magnetic switch.
8. Loosen the brush holder fixing screws and the
through bolt.
9. Remove the rear bracket and gasket.
10. Discard the gasket.
11. Use a socket wrench with a 32 mm diameter to hold
the armature commutator in place. Remove the yoke
assembly.
12. Slide the brush on to the socket.
13. Lift the brush spring and remove the brush.
14. Remove the brush holder.
15. Pull the armature from the planetary gear.
16. Use a bearing puller to remove the bearing. Be
careful not to lose the ball.
17. Remove the plate and gasket.
18. Remove the planetary gear.
19. Hold the internal gear, the gear shaft overrunning
clutch, and the lever together. Remove them as a
unit from the front bracket.
20. Remove the lever from the gear shaft (mark its
installation position).
21. Remove the E-type stop ring from the gear shaft and
discard it.
22. Remove the overrunning clutch from the gear shaft.
23. Remove the internal gear and washers.
SW 1
SW 2
24 V
060EY00014
1
2
3
4
5
6
060EY00015