STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A01VJ43

      Apply high-temperature grease to the bushing and spline of the starter clutch sub-assembly and stop collar.

      Text in Illustration
      A01VL3H High-temperature Grease
    2. A01VLGVE02
      Text in Illustration
      *1 Stop Collar
      *2 Starter Clutch Sub-assembly
      *a Cross Section Drawing
      A01VL3H Starter Clutch Sub-assembly Side

      Place the starter clutch sub-assembly and stop collar to the starter armature assembly.

    3. A01VIOKE01
      Text in Illustration
      *1 Snap Ring
      *a Cross Section Drawing

      Apply high-temperature grease to a new snap ring, and install it to the groove of the starter armature assembly.

    4. Using a vise between aluminum plates, compress the snap ring.

      Note

      Do not overtighten the vise.

    5. A01VGX3E02
      Text in Illustration
      *1 Snap Ring
      *2 Stop Collar
      *a Cross Section Drawing

      Using a plastic-faced hammer, while holding the starter clutch sub-assembly, tap the starter armature assembly and engage the stop collar to the snap ring.

      Note

      Do not tap the starter armature assembly too strongly.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01VL85

      As shown in the illustration, push out the 4 brushes of the starter yoke assembly towards the outer side and them there.

      A01VL3H Push Out
    2. A01VHW9

      Install the starter armature assembly to the starter yoke assembly.

    3. Secure the starter armature assembly shaft in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    4. A01VKW4

      Install the 4 brush springs.

      Note

      Make sure the brush spring does not fly out.

    5. A01VDVF

      Install the brush holder insulator to the brush holder of the starter yoke assembly.

  3. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01VIBU

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

      Note

      While holding down the lead wire, install the starter commutator end frame assembly.

    2. A01VI2ZE02
      Text in Illustration
      *1 Rubber Seal
      *2 Starter Pinion Drive Lever
      *3 Starter Commutator End Frame Assembly.
      *4 Starter Yoke Assembly
      *5 Starter Clutch Sub-assembly
      *6 Starter Drive Housing Assembly
      A01VL3H High-temperature Grease

      Apply high-temperature grease to the parts of the starter pinion drive lever that contact the magnet starter switch assembly, starter clutch sub-assembly and starter drive housing assembly.

    3. Install the starter pinion drive lever to the starter clutch sub-assembly.

    4. Install the starter commutator end frame assembly together with starter yoke assembly, starter pinion drive lever and rubber seal to the starter drive housing assembly.

    5. A01VHWS

      Install the 2 through bolts.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  4. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01VLV2

      Install the return spring to the starter pinion drive lever.

    2. A01VFPF

      Using "TORX" socket wrench T20, install the magnet starter switch assembly to the starter drive housing assembly with the 2 bolts.

      Torque:
      3.8 N*m  { 39 kgf*cm, 34 in.*lbf }
    3. A01VL70

      Install the wire harness to the terminal 45 with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }