STARTER (for Cold Area) REASSEMBLY


  1. REMOVE PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A0137P6E01

      Install the planet carrier shaft to the planet carrier.

    2. Install the washer to the planet carrier shaft.

    3. A01362X

      Using a screwdriver, install the snap ring to the planet carrier shaft.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A0136GKE01

      Apply grease to the spline of the starter clutch and the planet carrier shaft.

    2. Install the starter clutch to the planet carrier shaft.

    3. A01367QE01

      Apply grease to the snap ring and pinion stop collar.

    4. Install the pinion stop collar and new snap ring.

    5. A0136L5E01

      Using a vise, compress the snap ring.

    6. A0138C9E01

      Using a plastic hammer, lightly tap the planet carrier shaft so that the pinion stop collar is beyond the snap ring while holding the outside of the starter clutch by hand.

    7. A0136LYE01

      Install the starter center bearing clutch, pinion drive lever and starter drive housing cover to the starter drive housing.

    8. A0135UYE01

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

    9. Install the 3 planetary gears to the planet carrier.

  3. REMOVE STARTER ARMATURE ASSEMBLY


    1. A0138NRE01

      Install the starter armature to the starter yoke.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A0138JSE01

      Hold the starter yoke in a vise with aluminum plates in between.

      Note

      Do not overtighten the vise.

    2. While compressing the spring, install the starter brush holder to the starter armature.

      Note

      Align the cutout of the starter yoke and the rubber and install the starter brush holder.

    3. A0138ADE01

      Install the starter commutator end frame to the starter yoke.

    4. Install the washer to the starter commutator end frame.

    5. A0136EUE01

      Install the slotted washer.

    6. A01377R

      Install the starter commutator end frame cover to the starter commutator end frame with the 2 screws.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01375HE01

      Fit the 3 claws of the plate into the 3 grooves of the planet carrier and install the plate to the planet carrier.

    2. A0138KME01

      Align the groove of the yoke and the starter drive housing cover and install the starter yoke to the starter drive housing.

    3. A0137A2

      Install the starter yoke to the starter drive housing with the 2 bolts.

      Torque:
      4.8 N*m  { 48 kgf*cm, 42 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01381HE01

      Apply grease to the hook.

    2. Install the plunger to the pinion drive lever.

    3. A0137EK

      Install the return spring to the magnet starter switch.

    4. Using a "torx" socket wrench (T25), install the magnet starter switch with the 3 screws.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    5. A0137M7

      Connect the lead wire to the terminal with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }