STARTER (for 2.2 kW Type) REASSEMBLY


  1. INSTALL STARTER TERMINAL KIT

    A01KGA6E01

    1. Temporarily install new terminal 30 kit parts.

      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 Inside
      *b Short
      *c Long

      Tech Tips


      • Install the packing to the terminal insulator, and install them.

      • Match the protrusion of the insulator with the indentation of the housing.

    2. A01KEZCE01
      Text in Illustration
      *1 Terminal insulator (inside)
      *2 Contact plate
      *3 Terminal bolt
      *4 O-ring
      *5 Terminal insulator (outside)
      *6 Wave washer
      *7 Terminal nut
      *a Inside
      *b Short
      *c Long

      Temporarily install these new terminal C kit parts.

    3. A01KHDEE01
      Text in Illustration
      *1 Contact Plate
      *2 Wooden Block
      *a 20 mm
      *b 37 mm
      *c 40 mm

      Tighten terminal nuts.


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

        Dimensions 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 the 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  { 173 kgf*cm, 13 ft.*lbf }

      Note

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

    5. A01KGXV

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

    6. Reinstall the plunger, a new gasket, the end cover and lead clamp with the 3 bolts.

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

  2. INSTALL STARTER BEARING (Front)

    A01KF11

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

      SST
      09201-41020

  3. INSTALL STARTER BEARING (Rear)

    A01KHRKE01
    Text in Illustration
    *a Upward
    *b Downward
    *c 10 mm nut

    1. Using a 10 mm (for thread diameter) nut and press, install a new bearing.

      Note

      Be careful of the bearing direction.

    2. A01KFGQ

      Using a punch, stake the armature shaft.

  4. INSTALL STARTER ARMATURE ASSEMBLY

    A01KG9O

    1. Using a press, install the armature assembly.

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    A01KGGZ

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

    2. Place the brush holder on the starter yoke assembly.

    3. A01KG3L

      Using a screwdriver, hold the brush spring back.

    4. Connect the brush into the brush holder.

    5. Connect the 4 brushes.

      Note

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

    6. Install a new O-ring to the groove of the starter yoke.

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. Apply grease to the steel ball, return spring, clutch rollers and starter idler pinions.

    2. Install the steel ball.

    3. Insert the return spring into the magnet starter switch hole.

    4. A01KEEPE06

      Install the starter clutch sub-assembly.

    5. Install the 5 clutch rollers and retainer.

    6. Install the 2 starter idler pinions.

    7. A01KFH2

      Install the starter housing to the magnet switch assembly with the 2 screws.

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

  7. INSTALL STARTER YOKE ASSEMBLY

    A01KGXCE02
    Text in Illustration
    *a Align

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

    2. Align the claws of the brush holder with the grooves of the magnet starter switch.

    3. Install the starter yoke assembly with the armature assembly.

    4. Align the punch mark of the starter yoke with the line of the magnet starter switch.

    5. A01KHTLE05
      Text in Illustration
      *1 New Dust Protector

      Install the 2 new O-rings and 2 long bolts.

      Torque:
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

    6. Connect the terminal C wire with the nut.

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

    7. Install 2 new dust protectors.

    8. Install the terminal 50 wire with the screw.

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