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5-30 AI043 11. Carefully place the starter case and armature assembly into the commutator cap. Again, check to make sure the scribed marks of these two com- ponents are aligned. With the case flat on the assembly tool, slowly pull the tool from the starter motor. The case should then drop into place. AI044 12. Apply red Loctite #271 to the threads of the two through-bolts; then install and secure the bolts. Tighten to 1-1.4 kg-m (7-10 ft-lb). NOTE: The starter shouldn’t be picked up until DISASSEMBLING PINION 1. Remove the dust cap from the end of the pinion drive by first pulling straight out and then twisting the dust cap to the side. 2. Place a 11 mm or a 7/16 in. socket over the end of the pinion shaft and tap the socket gently with a hammer. NOTE: This procedure will dislodge the snap-ring 3. Using a side cutter, diagonal cutter, or suitable pli- ers, remove and discard the snap ring. 4. Remove the snap-ring retainer (note end-for-end orientation), pinion spring, spring retainer, and pinion gear. Retain all components. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, 1. Using parts-cleaning solvent, wash grease from the pinion gear. Dry with compressed air. 2. Inspect the pinion gear for wear. If the gear is worn or chipped, replace the pinion assembly. 3. Inspect the inner gear and housing. If the gear shows any signs of wear, replace the pinion assem- bly. 4. Inspect the inner housing for tightness and cracks. If the housing shows any signs of being loose or cracked, replace the pinion assembly. 5. Inspect the pinion return spring for wear. If the spring shows any worn areas, replace the spring. ASSEMBLING/INSTALLING PINION 1. Slide the pinion gear, spring retainer, pinion spring, and snap-ring retainer (note end-for-end orientation) onto the shaft in their original posi- tions. 2. Place new snap ring over the end of the pinion shaft; then slide the snap ring over the shaft. Using a 11 mm or 7/16 in. socket and a hammer, gently tap the snap ring into the groove on the shaft. 3. Slide the dust cover over the pinion assembly being careful not to dislodge the grease. Firmly push the dust cover until it snaps into its retaining groove. TESTING STARTER MOTOR NOTE: Before installing the starter motor, per- 1. Attach a black jumper cable to a good ground on the starter. 2. Attach the opposite end of the black jumper cable to the negative post of a good 12V battery. 3. Attach the red jumper cable to the positive post of the battery. ! WARNING When using compressed air to dry components, |