STARTER REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. B003WARC02
      B003WAF High-temperature Grease

      Apply high-temperature grease to the drive lever set pin as shown in the illustration.

    2. B003UGEC03
      *1 Drive Lever Set Pin
      *2 Starter Center Bearing Clutch Sub-assembly

      Install the drive lever set pin onto the starter center bearing clutch sub-assembly.

    3. Install the starter center bearing clutch sub-assembly with drive lever set pin to the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR


    1. B003W44C02
      B003WAF High-temperature Grease

      Apply high-temperature grease to the planetary gears and planetary shaft pins.

    2. Install the 3 planetary gears.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Hold the starter commutator end frame assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vice.

    2. B003WWDC03
      B003WAF High-temperature Grease

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

    3. B003WMLC02
      B003WAF High-temperature Grease

      Apply high-temperature grease to the armature shaft.

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

    5. B003VTRC02
      *a Snap Ring Pliers

      Using snap ring pliers, install the 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.

    6. B003W9UC04
      *a Length

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

      Maximum Length
      5.0 mm (0.197 in.)

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

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


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

  5. INSTALL STARTER ARMATURE PLATE


    1. B003U8ZC04
      *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.

  6. INSTALL STARTER YOKE ASSEMBLY


    1. B003VNNC03
      *a Rubber
      *b Cutout

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

  7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B003TCQC03
      *a Protrusion
      *b Cutout

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

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

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

  8. INSTALL REPAIR SERVICE STARTER KIT


    1. B003UWCC01
      B003WAF High-temperature Grease

      Apply high-temperature grease to the plunger.

    2. Hang the hook of the plunger on the drive lever set pin.

    3. Install the plunger and return spring.

    4. Install the magnet switch with the 2 screws.

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

    5. Connect the lead wire to the magnet switch with the nut.

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