STARTER REASSEMBLY

PROCEDURE


  1. INSTALL PLANETARY GEAR


    1. B006LBPC01
      B006QOD High-temperature Grease

      Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter drive housing assembly.

    2. Install the 3 planetary gears to the starter drive housing assembly.

  2. INSTALL RUBBER SEAL


    1. B006PQ8

      Install the rubber seal to the starter drive housing assembly.

  3. INSTALL STARTER ARMATURE ASSEMBLY


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

      Note

      Do not overtighten the vise.

    2. B006P8SC01
      B006QOD High-temperature Grease

      Apply high-temperature grease to the starter armature shaft.

    3. B006LI9C02
      B006QOD High-temperature Grease

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

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

    5. B006LBQC02
      *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 starter armature shaft groove securely.

      • Do not expand the snap ring excessively.

    6. B006NMRC10
      *a Width

      Using a vernier caliper, measure the width of the snap ring end gap as shown in the illustration.

      Maximum Width
      5.0 mm (0.197 in.)

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

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. B006RI4

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

  5. INSTALL STARTER ARMATURE PLATE


    1. B006MPDC13
      *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 COMMUTATOR END FRAME ASSEMBLY

    B006P6SC06
    *a Rubber
    *b Cutout

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

  7. INSTALL STARTER YOKE ASSEMBLY


    1. B006OXUC04
      *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 MAGNET STARTER SWITCH ASSEMBLY


    1. B006NWWC01
      *a Hook
      *b Pinion Drive Lever
      B006QOD High-temperature Grease

      Apply high-temperature grease to the magnet starter switch assembly.

    2. Hang the hook of the magnet starter switch assembly on the pinion drive lever.

    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 field coil lead wire to the magnet starter switch assembly with the nut.

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