STARTER(w/ Stop And Start System) REASSEMBLY

PROCEDURE


  1. INSTALL DUST STARTER PROTECTOR


    1. A00Y8G5

      Install the dust starter protector to the starter yoke assembly.

  2. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A00YAXFC01
      A00Y51D High-temperature Grease

      Apply high-temperature grease to the starter pinion drive lever which is in contact with the starter pivot part of the starter pinion drive lever.

    2. A00YB34C04
      *1 Starter Pinion Drive Lever
      *2 Starter Center Bearing Clutch Sub-assembly

      Install the starter pinion drive lever into the starter center bearing clutch sub-assembly.

    3. Install the starter center bearing clutch sub-assembly together with the starter pinion drive lever into the starter drive housing.

    4. A00Y95T

      Install the rubber seal to the starter drive housing.

  3. INSTALL PLANETARY GEAR


    1. A00Y5WGC01
      A00Y51D High-temperature Grease

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

    2. Install the 3 planetary gears.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A00Y96M

      Install the starter armature assembly to the starter yoke assembly.

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A00Y7E0

      Push out the 4 brushes from the brush holder assembly so that they are held in place by the springs as shown in the illustration.

    2. A00Y9XV

      Install the starter brush holder assembly to the starter armature and push in the 4 brushes as shown in the illustration.

    3. A00Y8A7C04
      *a Grommet
      *b Plate (Positive Side)
      *c Ground Plate (Negative Side)

      Insert the grommet between the ground plate and plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A00Y8J1

      Engage the clamp of the starter brush holder assembly with the starter commutator end frame assembly.

    2. Install the starter commutator end frame assembly with the 2 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

  7. INSTALL STARTER ARMATURE PLATE


    1. Install the starter armature plate onto the starter yoke assembly.

    2. Install the starter armature plate so that the cutout is positioned between the tabs.

      A00Y51QC01
      *a Tab *b Cutout

  8. INSTALL STARTER YOKE ASSEMBLY


    1. A00YAQLC02
      *a Tab
      *b Cutout
      *c Rubber Seal

      Align the tab of the starter yoke assembly with the cutout of the starter drive housing.

    2. A00Y8DY

      Using a T25 "TORX" socket wrench, install the starter yoke assembly with the 2 through bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A00Y9CJC02
      *1 Starter Pinion Drive Lever
      *a Plunger Hook
      A00Y51D High-temperature Grease

      Apply high-temperature grease to the plunger hook.

    2. Connect the plunger hook to the starter pinion drive lever.

    3. A00YALB

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A00Y9DE

      Connect the 2 lead wires to the magnet starter switch assembly with the nut.

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

  10. INSTALL STARTER TERMINAL


    1. A00YB0J

      Install the starter terminal with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. Close the terminal cap.