STARTER (for 2.7 kW Type) REASSEMBLY


  1. INSTALL STARTER TERMINAL KIT

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    1. Install new terminal 30 kit parts.

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

      Note

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

    2. A01KIFCE01
      Text in Illustration
      *1 Terminal insulator (inside)
      *2 Contact plate
      *3 Terminal bolt
      *4 Packing and terminal insulator (outside)
      *5 Wave washer
      *6 Terminal nut
      *7 Lead Terminal
      *a Long
      *b Short
      *c Inside

      Temporarily install new terminal C kit parts.

      Tech Tips

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

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

      A01KFJGE01
      Text in Illustration
      *1 Wooden Block
      *2 Contact Plate
      *a 20 mm
      *b 37 mm
      *c 40 mm
      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.

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      • 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.

      SST
      09810-38170
      Torque:
      30 N*m  { 305 kgf*cm, 22 ft.*lbf }

      Note

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

    5. A01KHYH

      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 (Front)

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    Text in Illustration
    *a Upward
    *b Downward

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

      SST
      09820-00030

  3. INSTALL STARTER BEARING (Rear)

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

      SST
      09820-00030

  4. INSTALL STARTER ARMATURE ASSEMBLY

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY

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

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


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

    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 starter idle pinion.

    6. A01KHPU

      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

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    1. Place the felt washer on the armature shaft.

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

    3. A01KGTUE01
      Text in Illustration
      *1 Terminal C

      Install the starter yoke assembly with the 2 through bolts.

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

    4. Connect the terminal C wire with the nut.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Install 2 new dust protectors.