STARTER (for 1.7 kW Type) REASSEMBLY


  1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. Install the 3 damper rubbers and the intermediate sealing to the planet carrier.

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

    3. Install the washer to the planet carrier shaft.

    4. A003HER

      Using a screwdriver and hammer, tap on a new snap ring.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A003CE1E04

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

      Text in Illustration
      A003DCD MP grease

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

    3. A003IEZE04
      Text in Illustration
      *1 Snap Ring
      *2 Pinion Stop Collar
      A003DCD MP grease

      Apply MP grease to a new snap ring and the pinion stop collar.

    4. Install the pinion stop collar and snap ring.

    5. A003D4TE03
      Text in Illustration
      *1 Planet Carrier Shaft
      *2 Snap Ring

      Using a vise, compress the snap ring.

    6. A003BN7E03
      Text in Illustration
      *1 Snap Ring
      *2 Pinion Stop Collar

      Using a plastic-faced hammer, lightly tap the planet carrier shaft while holding the outside of the starter clutch sub-assembly by hand until the pinion stop collar and snap ring are as shown in the illustration.

    7. A003FP5E03

      Apply MP grease to the pinion drive lever.

      Text in Illustration
      A003DCD MP grease

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

    9. A003BZHE05

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

      Text in Illustration
      A003DCD MP grease

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

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the armature to the starter yoke.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A003HLIE03
      Text in Illustration
      *1 Rubber Part
      *2 Brush Holder
      *3 Spring

      Hold the starter yoke between aluminum plates in a vise.

      Note

      Do not damage the starter yoke.

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

      Note

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

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

    4. Install the washer to the commutator end frame.

    5. Apply MP grease to the slotted washer.

    6. Install the slotted washer.

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

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A003F88E03
      Text in Illustration
      *1 Groove
      *2 Claw

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

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

    3. Install the 2 bolts.

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

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A003B2YE04
      Text in Illustration
      *1 Pinion Drive Lever
      *2 Plunger
      A003DCD MP grease

      Apply MP grease to the hook.

    2. Install the plunger to the pinion drive lever.

    3. Install the return spring to the magnet starter switch.

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

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

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

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