1987 MAZDA 626 clutch

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
86U05X-034
Snap ring
Internal gear
Drive pinion I Gear shaft
r i
rt
n I I Washer

OC
Stopper
7BU05X-037
Overrunning Clutch Stopper
1. Remove the overrunning clutch stopper using a
pipe.
2. Disassemble the drive pinion, internal gear and
washer from the gear shaft.
Brush and Brush Holder
Remove the brush from the brush holder using a flat-
tip screwdriver.
7BU05X-038
5-48

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Overrunning Clutch
Turn the pinion shaft by hand and hold the overrun-
ning clutch.
Replace the overrunning clutch if the pinion turns in
both directions or in neither direction.
Note
Do not wash the overrunning clutch with sol-
vent; it is packed with grease and sealed.
86U05X-035
Internal Gear and Planetary Gears
1. Internal gear
Check for wear or damage. Replace if necessary.
2. Planetary gears
Check for wear or damage. Replace if necessary.
67U05X-057
Yoke
Check for damage. Replace if necessary.
67U05X-058
Bearing
Check for abnormal noise, looseness, binding.
Replace the bearing if there is any problem.
Note
Use a bearing puller to remove the bearings.
67U05X-059
5-51

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
86U05X-037
Internal gear
Drive pinion Gear shaft
Snap ring
Stopper
7BU05X-045
Snap ring
Stopper
Overrunning
\= clutch
7BU05X-046
ASSEMBLY
Assemble in the reverse order of disassembly, refer-
ring to the assembly note.
Assembly Note
Lubricate
During assembly lubricate the following points:
1. Gear of armature shaft
2. Internal gear and planetary gears
3. Plunger circumference
4. Lever
5. Ball
6. Gear shaft spline
7. Front bracket housing
Installation of Overrunning Clutch
1. Install the washer, internal gear, drive pinion stop-
per, and the snap ring on the gear shaft.
2. Press the stopper and the snap ring into position
as shown in the figure.
Installation of lever
Check the lever faces in the correct direction.
7BU05X-047
5—53

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
7BU05X-048
86U05X-038
7BU05X-050
Installation of Brush Holder
Install the brush holder assembly and rear cover and
align the through bolts.
CHECKING OPERATION
Magnetic Switch
Make the following tests:
Pull-out test
1. Check that the pinion is pulled out when 12V is con-
nected to the S terminal and the body is grounded.
2. Measure the pinion gap while the pinion is pulled
out.
Specification: 0.5—2.0 mm (0.02—0.08 in)
3. Adjust the pinion gap with an adjust washer (drive
housing front cover—magnetic switch) if it is not
within specification.
Return test
1. Disconnect the motor wire from the M terminal, and
then connect the battery power to the M terminal
and ground the body.
2. Pull out the overrunning clutch with a flat-tip screw-
driver. Check that the overrunning clutch returns
to its original position when released.
86U05X-039
5-54

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-044
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
4BG05X-047
1. Yoke assembly 7. Over-running clutch assembly
2. Brush holder 8. Pinion gear
3. Armature 9. Steel ball
4. Magnetic switch assembly 10. Coil spring
5. Idler gear 11. Housing
6. Retainer and rollers
5—57

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
9. Remove the over-running clutch assembly from the
housing.
4EG05X-048
10. Remove the steel ball from the over-running clutch
assembly.
Caution
Be careful not to lose the steel ball.
4EG05X-049
y
/

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Coil spring Magnet switch
11. Remove the coil spring from the magnetic switch.
4EG05X-050
Assembly (main point)
Greasing
Apply grease (lithium base, NLGI No. 2) to the places
shown in the figure.
4BG05X-099
5—60

STARTOR (DIESEL ENGINE, 2.0 kW TYPE) 5
Coil spring and steel ball installation
1. Install the coil spring and steel ball to the magnet-
ic switch before installing the over-running clutch
assembly.
2. Assemble the retainer and roller to the idler gear.
4BG04X-100
Brush
(
+
)

Brush installation
1. Assemble the brush holder to the yoke.
2. Assemble the two brushes on the yoke side to the
brush holder.
4BG05X-101
Magnetic switch installation
Align the cut out part with the projection of the mag-
netic switch.
4BG05X-102
INSPECTION
Armature Coil
1. Ground of the armature coil
(1) Check for continuity between the commutator
and the core by using a circuit tester.
(2) Replace the armature if there is continuity.
4BG05X-081
5-61

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-046
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly in the reverse order of disassembly.
4BG05X-107
1. Magnetic switch 7. Lever
2. Rear cover 8. Cover
3. Brush-holder assembly 9. Drive pinion and over-running
4. Yoke clutch assembly
5. Armature 10. Reduction gear
6. Front housing 11. Center bracket
5—67