STARTER REASSEMBLY

Tech Tips

Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter.


  1. INSTALL PLANETARY GEAR


    1. A01HP08E16

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

      Text in Illustration
      A01HNYE High-temperature grease

    2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01HP3LE10

      Apply grease to the armature shaft.

      Text in Illustration
      A01HNYE High-temperature grease
    2. A01HO3SE04

      Apply high-temperature grease to the plate washer and bearing, as shown in the illustration.

      Text in Illustration
      A01HNYE High-temperature grease

    3. Install the starter armature to the starter commutator end frame.

    4. A01HQXBE12
      Text in Illustration
      *a Snap Ring Pliers

      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 expands easily.

    5. A01HOK3E33
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the length of the snap ring.

      Maximum length
      5.0 mm (0.196 in.)

      If the length is greater than the maximum, replace it with a new snap ring.

  3. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A01HP2P

      Install the end frame cover to the commutator end frame.

  4. INSTALL STARTER ARMATURE PLATE


    1. A01HO9GE28
      Text in Illustration
      *a Keyway
      *b Key

      Insert the starter armature plate to the starter yoke.

    2. Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01HQ2NE15
      Text in Illustration
      *a Cutout
      *b Rubber

      Align the rubber of the end frame with the cutout of the starter yoke.

    2. Install the 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 to break.

  6. INSTALL STARTER YOKE ASSEMBLY


    1. A01HMPYE14
      Text in Illustration
      *a Cutout
      *b Protrusion

      Align the protrusion of the starter yoke with the cutout of the starter drive housing.

    2. A01HN9B

      Install the starter yoke with the 2 through-bolts.

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

  7. INSTALL REPAIR SERVICE STARTER KIT


    1. A01HOS1E06

      Apply grease to the plunger and the hook.

      Text in Illustration
      A01HNYE High-temperature grease

    2. Hang the plunger hook of the magnetic switch to the drive lever.

    3. Install the plunger and return spring.

    4. A01HOZ9

      Install the magnetic switch with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01HP5P

      Connect the lead wire to the magnetic switch with the nut.

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