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9-2. Disassembly
(1) Disassembly of the armature
1) Loosen the Tapping Screw (W/Flange) D4 x 20 (Black) [53] <53> to pull out the Tail Cover [52] <52>.
2) Remove the two Carbon Brushes [40] <40> from the Brush Holders [41] <41>.
3) Loosen the four Tapping Screws D5 x 25 [1] <1> which fix the Gear Cover Ass'y [4] <4> to remove the
Armature [9] <9> from the Housing [35] <35> together with the Bearing Holder [8] <8>.
4) Loosen the Special Nut M7 [5] <5> which fixes the Pinion [6] <6> to remove the Pinion [6] <6>.
5) Insert the hooks of the J-204 bearing puller between the Ball Bearing [7] <7> and the Bearing Holder [8]
<8> from both sides and fix the hooks with the wing bolts.
6) Place the J-204 bearing puller on a supporting jig and push down on the tip of the armature shaft with a
hand press to remove the Ball Bearing [7] <7>. Then remove the Bearing Holder [8] <8>.
(2) Disassembly of the dust seal
1) Remove the Magnet [38] <38>. (Note that the magnet is left-hand threaded.)
2) Insert the hooks of the J-204 bearing puller between the commutator and the Dust Seal [14] <14> from both
sides, and fix the hooks with the wing bolts.
3) Place the J-204 bearing puller on a supporting jig and push down on the armature shaft with a hand press
to remove the Dust Seal [14] <14> together with the Ball Bearing [15] <15>. Replace the Dust Seal [14]
<14> with new one because it is damaged by the removal of the Ball bearing [15] <15>.
(3) Disassembly of the controller
1) Remove the Tail Cover [52] <52>. Disconnect the internal wire from the Switch [59] <59> and remove the
Connector [51] <51> and the Terminal [48] <48> from the internal wire.
2) Remove the neutral conductor of the Noise Suppressor [50] <50> from the Housing [35] <35>.
3) Remove the Tapping Screws [47] <47>, [56] <56>, [56A] <56A>, [60] <60>.
(NOTE) When removing the Tapping Screw (W/Flange) D4 x 16 [60] <60>, use a small-diameter screwdriver
(3.5 mm to 4.5 mm in diameter).
(4) Disassembly of the stator ass'y
1) Remove the Armature [9] <9> and then pull out the two Brush Holders [41] <41> from the Housing [35]
<35>.
2) Remove the Controller Set [45] <45> from the Housing [35] <35>.
3) Remove the internal wire coming from Stator (A) [12] <12> from the Brush Holder [41] <41>.
4) Remove the Fan Guide [10] <10> from the Housing [35] <35>.
5) Loosen the two Hex. Hd. Tapping Screws D4 x 70 [11] <11> to remove Stator (A) [12] <12> from the
Housing [35] <35>. If Stator (A) [12] <12> cannot be removed easily, heat the Housing [35] <35> to
about 60˚C. Then Stator (A) [12] <12> can be removed.
