STARTER (for 2.7 kW Type) REASSEMBLY


  1. INSTALL STARTER TERMINAL KIT

    A01KGAHE01

    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 Wide
      *b Narrow
      *c Protrusion
      *d Indentation

      Tech Tips


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

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

      Note

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

    2. A01KIL2E01
      Text in Illustration
      *1 Terminal insulator (inside)
      *2 Contact plate
      *3 Terminal bolt
      *4 Terminal insulator (outside)
      *5 Wave washer
      *6 Terminal nut
      *a Wide
      *b Narrow
      *c inside

      Temporarily install new terminal C kit parts.

      Note

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

    3. A01KH0BE01
      Text in Illustration
      *1 Insulation Washer
      *2 Plunger Hole

      Align the plunger holes of the insulation washer and magnet starter switch housing.

    4. A01KI3IE01
      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.

    5. Using SST, tighten the nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

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

    6. A01KEF4

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

    7. 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)

    A01KE9OE02
    Text in Illustration
    *a Upward
    *b Downward

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

      SST
      09285-76010

      Note

      Be careful to the bearing direction.

  3. INSTALL STARTER BEARING (Rear)

    A01KGXLE01

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

      SST
      09285-76010

  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:
      3.6 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, clutch rollers and starter idler pinion.

    2. Install the steel ball.

    3. A01KFCBE01
      Text in Illustration
      *1 Return spring
      *2 Starter clutch sub-assembly
      *3 Plate washer
      *4 5 clutch rollers and retainer
      *5 Starter idler pinion
      *a Claw
      *b Groove

      Install the return spring.

    4. Install the starter clutch sub-assembly.

    5. Align the claw of the plate washer with the groove of the magnetic switch and install the plate washer.

    6. Install the 5 clutch rollers and retainer.

    7. Install the starter idler pinion.

    8. A01KEQN

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

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

  7. INSTALL STARTER YOKE ASSEMBLY

    A01KF5YE01
    Text in Illustration
    *1 Felt Washer
    *a Align

    1. Install the felt washer to the armature shaft.

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

    3. A01KGH3E01
      Text in Illustration
      *1 Terminal C
      *2 Terminal 50

      Install the starter yoke assembly with the 2 long 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 the terminal 50 wire with the screw.

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

    6. Install 2 new dust protectors.