STARTER (for 1.7 kW Type) REASSEMBLY

Tech Tips

Use high-temperature grease to lubricate the bearings, gears and return spring when assembling the starter.


  1. INSTALL PLANETARY GEAR


    1. B000LYXE16

      Apply 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 STARTER ARMATURE ASSEMBLY


    1. B000JD1E10

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

    4. B000JJWE12
      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. B000ILUE33
      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. B000IQK

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

  4. INSTALL STARTER ARMATURE PLATE


    1. B000JZKE28
      Text in Illustration
      *a Keyway
      *b Key

      Insert the starter armature plate to the starter yoke assembly.

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

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B000GXHE15
      Text in Illustration
      *a Cutout
      *b Rubber

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

  6. INSTALL STARTER YOKE ASSEMBLY


    1. B000HZOE14
      Text in Illustration
      *a Cutout
      *b Protrusion

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

    2. B000IRF

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

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

  7. INSTALL REPAIR SERVICE STARTER KIT


    1. B000K34E06

      Apply grease to the plunger and the hook.

      Text in Illustration
      B000K70 High-temperature grease

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

    3. Install the plunger and return spring.

    4. B000LHM

      Install the magnetic switch with the 2 screws.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. B000L1K

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

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