STARTER (for 1.6 kW Type) REASSEMBLY


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01BFOEE01

      Install the drive lever set pin to the starter center bearing clutch sub-assembly

    2. Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.

  2. INSTALL PLANET GEAR


    1. A01BD6R

      Apply grease to the planet gears and pin parts of the planet shaft.

    2. Install the 3 planet gears.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Apply grease to the plate washer and armature shaft.

    2. Install the armature shaft to the starter commutator end frame.

    3. A01BDT4E01

      Using snap ring pliers, install the plate washer and a new snap ring.

      Note


      • Be sure to install the snap ring in the armature shaft groove securely.

      • Be sure to properly install the snap ring because it easily expands.

    4. A01BF5UE01

      Using vernier calipers, measure the snap ring.

      Maximum length
      5.0 mm (0.197 in.)

      If the length is greater than the maximum, replace the snap ring.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A01BBK8E01

      Install the starter commutator end frame cover to the starter commutator end frame.

  5. INSTALL STARTER ARMATURE PLATE


    1. A01BBQAE01

      Align the claw of the armature plate with the groove inside the starter yoke, and install the starter armature plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01BBZ6E01

      Align the starter commutator end frame rubber with the groove of the starter yoke.

    2. Install the starter commutator end frame to the starter yoke.

      Note

      The magnet of the starter yoke may attract the starter armature when the starter commutator end frame is installed, causing the magnet break.

  7. INSTALL STARTER YOKE ASSEMBLY


    1. A01BGTEE01

      Align the claw of the starter yoke assembly with the groove inside the starter drive housing.

    2. A01BFIC

      Install the starter yoke assembly with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  8. INSTALL REPAIR SERVICE STARTER KIT


    1. Apply grease to the plunger and hook.

    2. A01BAE8

      Hang the plunger hook of the repair service starter kit to the drive lever.

    3. A01BBD1

      Install the repair service starter kit with the 2 screws.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    4. A01BCBJ

      Connect the lead wire to terminal C with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }