STARTER REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

Use high-temperature grease to lubricate the bearings and sliding parts when assembling the starter.

PROCEDURE


  1. INSTALL PLANETARY CARRIER SHAFT SUB-ASSEMBLY


    1. Install the planetary carrier shaft to the planetary carrier.

    2. Install the washer to the planetary carrier shaft.

    3. A002Q6X

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

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A002QXN

      Apply high-temperature grease to the splines of the starter clutch and planetary carrier shaft.

      Text in Illustration
      A002OPC High-temperature Grease

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

    3. A002QBIE08
      Text in Illustration
      *1 Snap Ring
      *2 Pinion Stop Collar

      Install the pinion stop collar and a new snap ring as shown in the illustration.

    4. A002N9GE06
      Text in Illustration
      *1 Planetary Carrier Shaft
      *2 Snap Ring

      Using a vise, compress the snap ring between aluminum plates.

    5. A002PNHE05
      Text in Illustration
      *1 Snap Ring
      *2 Pinion Stop Collar

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

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

    7. A002QSS

      Apply high-temperature grease to the planetary carrier.

      Text in Illustration
      A002OPC High-temperature Grease

    8. Install the 3 planetary gears to the planetary carrier.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the starter armature to the starter yoke.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Hold the starter yoke between aluminum plates in a vise.

      Note

      Do not damage the starter yoke.

    2. While compressing the springs, install the brush holder to the starter 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 high-temperature 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:
      1.4 N*m  { 14 kgf*cm, 12 in.*lbf }

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A002LRL

      Install the armature plate to the planetary carrier as shown in the illustration.

    2. A002QQLE02
      Text in Illustration
      *1 Drive Housing Cover
      *2 Groove

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

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

      Torque:
      4.8 N*m  { 49 kgf*cm, 42 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A002PW3E02
      Text in Illustration
      *1 Pinion Drive Lever
      *2 Plunger
      A002OPC High-temperature Grease

      Apply high-temperature grease to the hook of the plunger.

    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 }