STARTER REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter assembly.

PROCEDURE


  1. INSTALL PLANETARY GEAR


    1. A01W5MR

      Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.

      Text in Illustration
      B001O8N High-temperature grease

    2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01W1M4

      Apply high-temperature grease to the armature shaft.

      Text in Illustration
      B001O8N High-temperature grease
    2. A01W2TO

      Apply high-temperature grease to the washer and bearing as shown in the illustration.

      Text in Illustration
      B001O8N High-temperature grease

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

    4. A01W4K4E28
      Text in Illustration
      *a Snap Ring Pliers

      Using snap ring pliers, install the washer and a new snap ring.

      Note


      • Be sure to install the snap ring in the armature shaft groove securely.

      • Be sure to properly install the snap ring because it expands easily.

    5. A01W11HE40
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the length of the snap ring.

      Maximum length
      5.0 mm (0.197 in.)

      If the length is greater than the maximum, replace it with a new snap ring.

  3. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A01W2MN

      Install the starter commutator end frame cover to the starter commutator end frame assembly.

  4. INSTALL STARTER ARMATURE PLATE


    1. A01W42QE28
      Text in Illustration
      *a Keyway
      *b Key

      Insert the starter armature plate to the starter yoke assembly.

    2. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01W5E4E15
      Text in Illustration
      *a Cutout
      *b Rubber

      Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly.

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

      Note

      The magnet switch of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet switch to break.

    3. A01VZLYE22
      Text in Illustration
      *a Cutout
      *b Protrusion

      Align the protrusion of the starter yoke assembly with the cutout of the starter drive housing assembly.

    4. A01W2Q1

      Install the starter yoke assembly with the 2 through-bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  6. INSTALL REPAIR SERVICE STARTER KIT


    1. A01VZFN

      Apply high-temperature grease to the plunger.

      Text in Illustration
      B001O8N High-temperature grease

    2. Hang the hook of the plunger on the drive lever.

    3. A01W1W8

      Apply high-temperature grease to the return spring.

      Text in Illustration
      B001O8N High-temperature grease

    4. Install the plunger and return spring.

    5. A01W1XZ

      Install the magnet switch with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    6. A01W2CF

      Connect the lead wire to the magnet switch with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }