STARTER(for 2.2 kW Type) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH ASSEMBLY


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

    2. A01XLUO

      Insert the steel ball into the starter clutch hole.

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

    4. A01XL6IE02
      Text in Illustration
      *1 Return Spring
      *2 Starter Clutch
      *3 Idler Gear
      *4 Pinion Gear
      *5 Retainer
      *6 Clutch Roller
      *7 Starter Housing

      Install the starter clutch, idler gear, pinion gear, retainer and clutch roller to the starter housing.

    5. A01XFIP

      Install the starter housing to the magnet switch with the 2 bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. Apply high temperature grease to the starter armature bearing.

    2. A01XCML

      Using a press, press the starter armature into the starter yoke.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01XLW2E08
      Text in Illustration
      *1 Groove
      *2 Claw

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

    2. Place the brush holder on the starter yoke.

    3. Install the 4 starter yoke brushes to the starter brush holder.


      1. Using a screwdriver, pull back the spring.

      2. Install the brush to the brush holder.

        Note

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

  4. INSTALL STARTER YOKE ASSEMBLY


    1. Install a new O-ring to the groove of the starter yoke.

    2. A01XLCYE03
      Text in Illustration
      *1 Groove
      *2 Claw
      *3 Punch Mark

      Align the claws of the starter brush holder with the grooves of the magnet starter switch and install the starter yoke and starter armature.

    3. Align the punch mark of the starter yoke with the line of the magnet starter switch.

    4. A01XDPO
      Text in Illustration
      *1 O-Ring

      Install 2 new O-rings to the bolts.

    5. Install the starter yoke with the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

      Torque:
      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }