STARTER (for 1.6 kW Type) REASSEMBLY


  1. INSTALL PLANETARY GEAR


    1. B000INXE06

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

      Text in Illustration
      B000K70 High-temperature grease

    2. Install the 3 planetary gears.

  2. INSTALL RUBBER SEAL


    1. B000GYR

      Install the rubber seal to the repair service starter kit.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. B000JD1E10

      Apply high-temperature grease to the washer and the armature shaft.

      Text in Illustration
      B000K70 High-temperature grease
    2. B000LRCE04

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

      Text in Illustration
      B000K70 High-temperature grease
    3. B000MODE04
      Text in Illustration
      *1 Snap Ring Pliers

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

    4. Install the washer.

    5. Using snap ring pliers, securely install a new snap ring to the armature shaft groove.

      Note

      Be sure to install the snap ring, properly because it easily expands.

    6. B000M62E03
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the length of the snap ring.

      Maximum length
      5.0 mm (0.197 in.)

      If the length is more than the maximum, replace the snap ring with a new one.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. B000N11

      Install the starter commutator end frame cover to the starter commutator end frame assembly.

  5. INSTALL STARTER ARMATURE PLATE


    1. B000J81E03
      Text in Illustration
      *a Keyway
      *b Key

      Insert the armature plate into the starter yoke assembly.

    2. Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B000M98E03
      Text in Illustration
      *a Cutout
      *b Rubber

      Align the rubber of the end frame with the cutout of the starter yoke assembly.

    2. Install the starter commutator end frame assembly to the starter yoke assembly.

      Note

      The magnet of the starter yoke assembly may attract the starter armature when the starter commutator end assembly frame is installed, causing the magnet to break.

  7. INSTALL STARTER YOKE ASSEMBLY


    1. B000M9IE03
      Text in Illustration
      *a Protrusion
      *b Cutout

      Align the protrusion of the starter yoke assembly with the cutout of the repair service starter kit.

    2. B000MZH

      Install the starter yoke assembly with the 2 through-bolts.

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

  8. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. B000HEXE04

      Apply high-temperature grease to the plunger and the lever.

      Text in Illustration
      B000K70 High-temperature grease
    2. B000HNE

      Pull the pinion gear and push down the lever.

    3. B000KDGE03
      Text in Illustration
      *1 Plunger
      *2 Lever

      Temporarily install the magnet starter switch assembly by hooking the plunger into the upper side of the pinion drive lever.

    4. B000MRX

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. B000J8M

      Connect the lead wire to the magnet starter switch assembly with the nut.

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