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. A01HZKKE16

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

      Text in Illustration
      A01I0B8 High-temperature grease

    2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01HXM8E10

      Apply grease to the armature shaft.

      Text in Illustration
      A01I0B8 High-temperature grease
    2. A01I26AE04

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

      Text in Illustration
      A01I0B8 High-temperature grease

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

    4. A01I1UME12
      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. A01HY8YE33
      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. A01I1Q4

      Install the end frame cover to the commutator end frame.

  4. INSTALL STARTER ARMATURE PLATE


    1. A01HYFME28
      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. A01HZREE15
      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. A01HZ2LE14
      Text in Illustration
      *a Cutout
      *b Protrusion

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

    2. A01I0JD

      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. A01HYUCE06

      Apply grease to the plunger and the hook.

      Text in Illustration
      A01I0B8 High-temperature grease

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

    3. Install the plunger and return spring.

    4. A01I0L5

      Install the magnetic switch with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01I0DG

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

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