STARTER (for 2.0 kW Type) REASSEMBLY


  1. INSTALL STARTER TERMINAL KIT

    A01KFJ3E01
    Text in Illustration
    *1 Terminal insulator (inside)
    *2 Contact plate
    *3 Terminal bolt
    *4 O-ring
    *5 Packing and terminal insulator (outside)
    *6 Wave washer
    *7 Terminal nut
    *a Long
    *b Short

    1. Install new terminal 30 kit parts.

      Note

      Be careful to install the terminal insulator (inside) in the correct direction.

    2. A01KHJZE01
      Text in Illustration
      *1 Terminal insulator (inside)
      *2 Contact plate
      *3 Terminal bolt
      *4 O-ring
      *5 Packing and terminal insulator (outside)
      *6 Wave washer
      *7 Terminal nut
      *a Long
      *b Short

      Temporarily install new terminal C kit parts.

      Note

      Be careful to install the terminal insulator (inside) and wave washer in the correct direction.

    3. A01KHEME01
      Text in Illustration
      *1 Wooden Block
      *2 Contact Plate
      *a 20 mm
      *b 37 mm
      *c 40 mm

      Put a wooden block on the contact plate and press it down with a hand press.

      Dimension of wooden block
      20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
      Press force
      981 N (100 kgf, 221 lbf)

      Note


      • Check the diameter of the hand press ram. Then calculate the gauge pressure of he press when 981 N (100 kgf, 221 lbf) of force is applied.

        A01KEYA

      • If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.

    4. Using SST, tighten the nuts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

      Note

      If the nut is over tightened, it may cause cracks on the inside of the insulator.

    5. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.

    6. Install the plunger, a new gasket and the end cover with the 3 bolts.

      Torque:
      3.6 N*m  { 37 kgf*cm, 32 in.*lbf }

  2. INSTALL STARTER BEARING

    A01KHBPE01

    1. Using SST and a press, press in a new bearing.

      SST
      09820-00030

  3. INSTALL STARTER BEARING

    A01KE9OE02
    Text in Illustration
    *a Upward
    *b Downward

    1. Using SST and a press, press in a new bearing.

      SST
      09820-00030

      Note

      Be careful to the bearing direction.

  4. INSTALL STARTER ARMATURE ASSEMBLY

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    A01KH8V

    1. Place the brush holder on the armature.

    2. Using a screwdriver, install the 4 brushes.

    3. Install the end cover with the 2 screws.

      Torque:
      3.8 N*m  { 38 kgf*cm, 34 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. Apply the high-temperature grease to the steel ball, return spring, 5 clutch rollers and 2 starter idle pinions.

    2. Install the steel ball.

    3. Install the return spring.

    4. Install the starter clutch sub-assembly.

    5. Install the 5 clutch rollers, the retainer and 2 starter idle pinions.

    6. A01KEE7

      Install the magnet starter switch assembly with the 3 screws.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  7. INSTALL STARTER YOKE ASSEMBLY

    A01KG07

    1. Install a new O-ring to starter yoke assembly.

    2. Align the protrusion of the starter yoke assembly with the cutout of the magnet starter switch assembly.

    3. A01KH1C

      Install the starter yoke assembly with the 2 through bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }
    4. A01KIKY

      Connect the terminal C wire with the nut.

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