STARTER(w/o Stop And Start System) REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01CWXKC02
      A01CX8N High-temperature Grease

      Apply high-temperature grease to the areas of the starter pinion drive lever indicated in the illustration.

    2. Install the starter pinion drive lever and rubber seal to the starter center bearing clutch sub-assembly.

    3. Install the starter center bearing clutch sub-assembly together with the starter pinion drive lever and rubber seal to the starter drive housing assembly.

    4. A01CXQSC02
      A01CX8N High-temperature Grease

      Apply high-temperature grease to the planetary gears and pins of the starter center bearing clutch sub-assembly.

    5. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the starter armature assembly to the starter yoke assembly.

      Note

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

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01CYHO

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

    2. A01CWNP

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

      Note

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

    3. A01CW56C12
      *a Grommet
      *b Negative Side
      *c Positive Side

      Insert the grommet between the positive side and negative side.

  4. INSTALL STARTER YOKE ASSEMBLY


    1. A01CXSUC03
      *a Key A
      *b Key B

      Install the starter armature plate to the starter yoke assembly.

      Note

      Install the starter armature plate so that the keyway is positioned between key A and key B.

    2. A01CXPPC03
      *a Groove
      *b Cutout

      Align the groove of the lead wire with the cutout of the starter commutator end frame assembly.

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

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    4. A01CXEVC03
      *a Claw
      *b Groove

      Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.

    5. Using a T25 "TORX" socket wrench, install the 2 through bolts.

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

  5. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01CX1RC02
      A01CX8N High-temperature Grease

      Apply high-temperature grease to the plunger hook.

    2. Hang the plunger of the magnet starter switch assembly onto the drive lever from the upper side.

    3. Install the magnet starter switch assembly with the 2 nuts.

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

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

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