STARTER REASSEMBLY


  1. INSTALL DUST STARTER PROTECTOR


    1. Install the dust starter protector to the starter drive housing.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A01CISU

      Apply high-temperature grease to the starter clutch sub-assembly and starter planetary shaft sub-assembly as shown in the illustration.

      Text in Illustration
      A01CHW8 High-temperature Grease

    2. Align the grooves of the starter clutch sub-assembly and the starter planetary shaft sub-assembly and install the starter clutch sub-assembly.

    3. A01CH8E

      While pushing the starter clutch sub-assembly and starter planetary shaft sub-assembly together, slightly turn the starter clutch sub-assembly as shown in the illustration.

    4. Check that the starter clutch sub-assembly is installed securely to the starter planetary shaft sub-assembly by pulling up the clutch.

    5. Install the starter plate.

    6. Lift up the starter clutch sub-assembly. Using needle nose pliers, install the clip.

    7. A01CI4M

      Apply high-temperature grease to the pinion drive lever and starter clutch sub-assembly as shown in the illustration.

      Text in Illustration
      A01CHW8 High-temperature Grease

    8. Install the pinion drive lever.

    9. Install a new switch gasket.

    10. A01CH4J

      Apply high-temperature grease to the starter clutch sub-assembly and starter drive housing as shown in the illustration.

      Text in Illustration
      A01CHW8 High-temperature Grease

    11. Install the starter drive housing with the 2 bolts.

      Torque:
      4.3 N*m  { 44 kgf*cm, 38 in.*lbf }

    12. Install the starter pinion assembly with a new retainer.

      Note

      Make sure that the retainer is in the groove of the starter pinion assembly.

  3. INSTALL STARTER YOKE ASSEMBLY


    1. Install 2 new rubber seals.

    2. A01CHDGE03
      Text in Illustration
      *1 Key
      *2 Keyway

      Align the key of the starter yoke assembly with the keyway of the starter motor housing, and install the starter yoke assembly to the starter motor housing.

  4. INSTALL STARTER ARMATURE ASSEMBLY


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

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Install the starter brush holder assembly to the starter armature assembly.

    2. A01CGPFE02
      Text in Illustration
      *1 Cutout
      *2 Alignment Mark

      Align the cutout of the starter brush holder assembly with the alignment mark on the lead wire.

    3. Connect the 4 brushes to the starter brush holder.


      1. Using a screwdriver with its tip wrapped with protective tape, hold back the spring.

      2. Connect the brush to the brush holder.

        Note

        Check that the positive (+) lead wires are not grounded.

    4. Apply high-temperature grease to the starter armature bearing.

    5. Apply high-temperature grease to the starter plate and install the starter plate.

    6. A01CHLLE03
      Text in Illustration
      *1 Alignment Mark
      *2 Key

      Align the alignment mark of the commutator end frame with the key of the starter yoke assembly.

    7. Align the screw holes in the commutator end frame and starter brush holder assembly and install the commutator end frame with the 2 bolts.

      Torque:
      4.3 N*m  { 44 kgf*cm, 38 in.*lbf }

    8. Install the 2 bolts.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    9. Connect the lead wire to terminal M with the 2 washers and nut.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }