STARTER (for 3.0 kW Type) REASSEMBLY


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. Apply high-temperature grease to the steel ball, return spring, clutch roller, retainer, pinion gear and idler gear.

    2. Insert the steel ball into the starter clutch hole.

    3. Insert the return spring into the starter clutch hole.

    4. Install the starter clutch, return spring, idler gear, pinion gear, retainer and clutch roller.

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

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A003EEC

      Apply high-temperature grease to the armature bearings.

    2. Using a press, press the armature into the commutator end frame.

    3. Install a new O-ring to the starter yoke.

    4. A003BKTE02
      Text in Illustration
      *1 Groove
      *2 Claw

      Align the groove of the commutator end frame with the claw of the starter yoke, and install the armature and commutator end frame.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A003G8GE02
      Text in Illustration
      *1 Groove
      *2 Claw

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

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

    3. Install the 4 brushes with the 4 screws to the starter brush holder.

      Torque:
      3.6 N*m  { 37 kgf*cm, 32 in.*lbf }
    4. A003HUU

      Connect the 4 brushes to the starter brush holder.


      1. Using a screwdriver, pull back the spring.

      2. Connect the brush to the brush holder.

        Note

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

    5. Install a new O-ring to the starter yoke.

  4. INSTALL STARTER YOKE ASSEMBLY


    1. A003FRUE01
      Text in Illustration
      *1 Claw
      *2 Groove

      Align the claw of the starter brush holder with the groove of the magnet starter switch and install the starter yoke to the magnet starter switch.

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

      Torque:
      14 N*m  { 145 kgf*cm, 10 ft.*lbf }

    3. Connect the lead wire to terminal C with the nut.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }