STARTER(except Cold Area) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY

    A01VI4OE01

    1. Apply grease to the bushing and spline of the starter clutch.

      Text in Illustration
      *1 Stop collar

    2. Place the starter clutch and inside stop collar on the armature.

    3. A01VF0JE01
      Text in Illustration
      *1 Snap ring

      Apply grease to the snap ring, and install it onto the armature shaft groove.

    4. Using a vise, compress the snap ring.

    5. A01VHVN

      Hold the starter clutch, tap the armature shaft and install the stop collar onto a new snap ring with a plastic-faced hammer.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. Hold the starter armature assembly of shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

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

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01VJ1T

      Push out the 4 brushes from the brush holder so that they are held in place by the springs, as shown in the illustration.

    2. A01VH05

      Install the brush holder plate.

  4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01VKA5

      Install the starter commutator end frame assembly.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01VLLC

      Apply high-temperature grease to the starter pinion driver lever which is in contact with the starter pivot part of the starter pinion drive lever.

      Text in Illustration
      A01VL3H High-temperature grease
    2. A01VDJU

      Install the starter yoke assembly with the 2 bolts.

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01VLGNE02
      Text in Illustration
      *1 Drive Lever
      *2 Plunger Hook
      A01VL3H High-temperature grease

      Apply high-temperature grease to the plunger hook.

    2. Connect the plunger hook to the starter pinion drive lever.

    3. A01VDRK

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }
    4. A01VEOR

      Connect the lead with to the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }