STARTER REASSEMBLY

PROCEDURE

1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY

   1. Install the 3 damper rubbers and the intermediate sealing to the planet carrier.

   2. Install the planet carrier shaft sub-assembly to the planet carrier.

   3. Install the washer to the planet carrier shaft sub-assembly.

   4. 

      Using a screwdriver and hammer, tap on a new snap ring.

      Table 1. Text in Illustration

      *1

      Snap Ring

2. INSTALL STARTER CLUTCH SUB-ASSEMBLY

   1. 

      Apply high-temperature grease to the spline of the starter clutch sub-assembly and the planet carrier shaft sub-assembly.

      Table 2. Text in Illustration

      High-temperature Grease

   2. Install the starter clutch sub-assembly to the planet carrier shaft sub-assembly.

   3. 

      Apply high-temperature grease to a new snap ring and the pinion stop collar.

      Table 3. Text in Illustration

      *1	Snap Ring
      *2	Pinion Stop Collar
      	High-temperature Grease

   4. Install the pinion stop collar and snap ring as shown in the illustration.

   5. 

      Using a vise, compress the snap ring.

      Table 4. Text in Illustration

      *1	Snap Ring
      *2	Planet Carrier Shaft Sub-assembly

   6. 

      Using a plastic-faced hammer, lightly tap the planet carrier shaft sub-assembly while holding the outside of the starter clutch sub-assembly by hand until the pinion stop collar and snap ring are as shown in the illustration.

      Table 5. Text in Illustration

      *1	Snap Ring
      *2	Pinion Stop Collar

   7. 

      Apply high-temperature grease to the pinion drive lever.

      Table 6. Text in Illustration

      High-temperature Grease

   8. Install the starter center bearing clutch, pinion drive lever and starter drive housing cover to the starter drive housing.

   9. 

      Apply high-temperature grease to the planetary gears and pin parts of the planet carrier shaft sub-assembly.

      Table 7. Text in Illustration

      High-temperature Grease

   10. Install the 3 planetary gears to the planet carrier.

3. INSTALL STARTER ARMATURE ASSEMBLY

   1. Install the starter armature assembly to the starter yoke assembly.

4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

   1. Hold the starter yoke assembly between aluminum plates in a vise.

      Note:

      Do not damage the starter yoke assembly.

   2. While compressing the springs, install the starter brush holder assembly to the starter armature assembly.

      Note:

      Align the cutout of the starter yoke assembly and the rubber part and install the starter brush holder assembly.

   3. Install the starter commutator end frame to the starter yoke assembly.

   4. Install the 2 washers to the starter commutator end frame.

   5. Apply high-temperature grease to the slotted washer.

   6. Install the slotted washer.

   7. Install the starter commutator end frame cover to the starter commutator end frame with the 2 screws.

5. INSTALL STARTER YOKE ASSEMBLY

   1. Attach the 3 claws and install the plate to the planet carrier.

   2. Attach the 3 claws and install the frame end cover to the plate.

   3. 

      Align the groove of the starter yoke assembly and the starter drive housing cover and install the starter yoke assembly to the starter drive housing.

      Table 8. Text in Illustration

      *1	Starter Drive Housing Cover
      *a	Groove

   4. Install the 2 bolts.

      6.3 N*m

      64 kgf*cm

      55 in.*lbf

6. INSTALL MAGNET STARTER SWITCH ASSEMBLY

   1. 

      Apply high-temperature grease to the hook of the plunger.

      Table 9. Text in Illustration

      High-temperature Grease

   2. Install the plunger to the pinion drive lever.

   3. Install the return spring to the magnet starter switch assembly.

   4. Using a T20 "TORX" socket wrench, install the magnet starter switch assembly with the 3 screws.

   5. Connect the field coil wire to terminal C with the nut.

      6.0 N*m

      61 kgf*cm

      53 in.*lbf