STARTER REASSEMBLY

PROCEDURE


  1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. A01QPEHC01
      *1 Damper Rubber
      *2 Planet Carrier
      *3 Intermediate Sealing

      Install the 3 damper rubbers and intermediate sealing to the planet carrier.

    2. A01QSO6C03
      *1 Planet Carrier
      *2 Planet Carrier Shaft Sub-assembly

      Install the planet carrier shaft sub-assembly to the planet carrier.

    3. A01QSXF

      Install the washer to the planet carrier shaft sub-assembly.

    4. A01QT5S

      Using a screwdriver, install a new snap ring to the planet carrier shaft sub-assembly.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A01QPD6C01
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the spline of the starter clutch sub-assembly and planet carrier shaft sub-assembly.

    2. Install the starter clutch sub-assembly to the planet carrier shaft sub-assembly.

    3. A01QSXIC01
      *1 Snap Ring
      *2 Pinion Stop Collar
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the pinion stop collar and a new snap ring.

    4. Install the pinion stop collar and snap ring.

    5. A01QTJ6C05
      *1 Planet Carrier Shaft Sub-assembly
      *2 Snap Ring

      Using a vise, compress the snap ring.

    6. A01QPUBC10
      *1 Snap Ring
      *2 Pinion Stop Collar

      While holding the starter clutch sub-assembly, lightly tap the planet carrier shaft sub-assembly and install the pinion stop collar onto the snap ring with a plastic hammer.

    7. A01QOZ1C02
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the pinion drive lever.

    8. A01QSROC01
      *1 Pinion Drive Lever
      *2 Starter Drive Housing Cover
      *3 Starter Drive Housing Assembly
      *a Starter Center Bearing Clutch

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

    9. A01QUDMC01
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the planetary gears and planetary gear shafts of the planet carrier shaft sub-assembly.

    10. Install the 3 planetary gears to the planet carrier shaft sub-assembly.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01QP2YC01
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly

      Install the starter armature assembly to the starter yoke assembly.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01QSFSC06
      *1 Starter Brush Holder Assembly
      *a Rubber
      *b Spring
      *c Cutout

      Secure the starter yoke assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    2. While compressing the springs, install the starter brush holder assembly to the starter armature assembly.

      Note


      • Align the cutout of the starter yoke assembly with the rubber and install the starter brush holder assembly.

      • Use caution to prevent the starter armature assembly from dropping.

    3. A01QTYWC07
      *a Washer
      *b Starter Commutator End Frame

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

      Note

      Use caution to prevent the starter armature assembly from dropping.

    4. Install the 2 washers to the starter commutator end frame.

      Note

      Use caution to prevent the starter armature assembly from dropping.

    5. A01QSCOC03
      *a Slotted Washer
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the slotted washer.

      Note

      Use caution to prevent the starter armature assembly from dropping.

    6. Install the slotted washer.

    7. A01QOWG

      Install the starter commutator end frame cover to the starter commutator end frame with the 2 screws.

      Torque:
      2.1 N*m  { 21 kgf*cm, 19 in.*lbf }

    8. Engage the 3 claws and install the plate to the planet carrier.

    9. Engage the 3 claws and install the frame end cover to the plate.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01QTLAC01
      *1 Starter Drive Housing Cover
      *a Cutout

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

    2. A01QPFG

      Install the starter yoke assembly to the starter drive housing assembly with the 2 through bolts.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01QUEQC01
      *1 Pinion Drive Lever
      *a Plunger
      *b Hook
      A01QRKS High-temperature Grease

      Apply high-temperature grease to the hook.

    2. Hang the hook of the plunger on the pinion drive lever.

    3. Install the return spring to the magnet switch.

    4. A01QRBO

      Using a T20 "TORX" socket wrench, install the magnet switch with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    5. A01QQYA

      Connect the field coil lead wire to terminal C with the nut.

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