STARTER (for 3.0 kW Type) REASSEMBLY


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. Apply grease to the steel ball, return spring, clutch roller, retainer, pinion gear and idler gear.

    2. A01KFSK

      Install the steel ball.

    3. Insert the return spring into the starter clutch hole.

    4. Insert the starter clutch, return spring, idler gear, pinion gear, retainer and clutch roller.

    5. Install the starter housing to the magnet starter switch with the 3 screws.

      Torque:
      11 N*m  { 115 kgf*cm, 8.5 ft.*lbf }

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01KI95

      Apply grease to the armature bearings.

    2. Using a press, press the armature into the commutator end frame.

    3. Install a new O-ring.

    4. A01KFZDE04
      Text in Illustration
      *1 Groove
      *2 Claw

      Align the claw of the starter yoke with the groove of the commutator end frame, and install the armature commutator end frame.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01KGD2E03
      Text in Illustration
      *1 Groove
      *2 Claw

      Align the claw of the brush holder with the claw groove of the starter yoke.

    2. Place the brush holder on the starter yoke.

    3. A01KET8

      Install the 4 brushes to the brush holder with the 4 screws.

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

      1. Using a screwdriver, pull back the spring.

      2. Install the brush to the brush holder.

        Note

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

    4. Install a new O-ring.

  4. INSTALL STARTER YOKE ASSEMBLY


    1. A01KG8O

      Align the claws of the starter brush holder with the grooves of the magnet starter switch, and install the starter yoke and magnet starter switch.

    2. Install the starter yoke and starter housing with the 2 bolts.

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    3. Connect the lead wire to terminal C with the nut.

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