STARTER(for 2.0 kW Type) REASSEMBLY

PROCEDURE


  1. INSTALL REPAIR SERVICE STARTER KIT


    1. B003R86

      Install the rubber seal to the repair service starter kit.

    2. B003P8HC01
      B003R2S High-temperature Grease

      Apply high-temperature grease to the planetary gears and pins of the repair service starter kit as shown in the illustration.

    3. Install the 3 planetary gears to the starter center bearing clutch sub-assembly.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the starter armature 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 is installed, causing the magnet to break.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. B003K3UC02
      *a Retainer

      When installing a new part:

      Note

      Do not remove the retainer.


      1. B003OU6C02
        *1 Starter Brush Holder Assembly
        *2 Starter Armature Assembly
        *a Retainer
        *b Push Starter Brush Holder Assembly in this Direction
        *c Push out Retainer in this Direction

        With the retainer installed, push the starter brush holder assembly onto the starter armature assembly.

        Note

        Be careful not to damage the brushes when pushing the starter brush holder assembly in place.

        Tech Tips

        Install the starter brush holder assembly as shown in the illustration, as the installation direction is fixed.

      2. Push the starter brush holder assembly onto the starter armature assembly while pushing out the retainer with the end of the starter armature assembly.

      3. B003NNIC02
        *a Retainer
        *b Push out Retainer in this Direction

        Push the starter brush holder assembly onto the starter armature assembly until the retainer is completely pushed out.

    2. B003J9TC02
      *a Holder Box
      *b Spring
      *c Brush
      *d Rubber Part
      *e Holder Plate
      *f Rounded Corner of Lead Wire Rubber Part

      When reinstalling:


      1. Set the spring inside the holder box. Then, push the brush inside the holder box in the orientation shown in the illustration.

        Note

        Install the holder boxes so the rounded corner of the rubber portion of the lead wire faces the holder plate.

        Tech Tips

        Install the holder boxes with their claws facing the holder plate.

      2. B003P5EC02
        *a Range for Wire Used to Fix Brush
        *b Brush
        *c Holder Box
        *d 1 mm or less
        *e Claw of the Holder Box

        With the brush pushed inside, use wire or similar material to fix the brush in the position shown in the illustration.

        Note


        • When fixing the brush in place using wire or similar material, be careful not todamage the brush.

        • Fix the brush in place so that it protrudes from the holder box by 1 mm or less.

      3. B003OW4C02
        *a Holder Plate
        *b Rounded Corner of Lead Wire Rubber Part
        *c Claw of the Holder Box

        Insert the claw of the holder box into the holder plate to fix the holder box in place.

        Note


        • Install the holder boxes so the rounded corner of the rubber portion of the lead wire faces the holder plate.

        • Check that the 4 claws of the holder boxes are fixed to the holder plate.

      4. B003NFUC02
        *1 Starter Brush Holder Assembly
        *2 Starter Armature Assembly
        *a Push Starter Brush Holder Assembly in this Direction
        *b Assembly in this Direction Wire

        Push the starter brush holder assembly onto the starter armature assembly, but leave enough room to remove the wire or similar material.

      5. Remove the 4 pieces of wire or similar material and then push the starter brush holder assembly all the way onto the starter armature assembly.

        Note

        When removing the wire or similar material, be careful not to damage the brush.

  4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B003N4SC04
      *a Rubber Part
      *b Starter Commutator End Frame Assembly

      Align the rubber part of the starter yoke assembly with the groove of the starter commutator end frame assembly.

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

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

  5. INSTALL STARTER YOKE ASSEMBLY


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

    2. B003KAZC03
      *a Protrusion
      *b Notch

      Check that the notch of the starter armature plate fits over the protrusion of the starter yoke assembly.

    3. B003O33C01
      *a Notch
      *b Protrusion

      Align the protrusion of the starter yoke assembly with the notches inside the repair service starter kit and insert the starter yoke assembly into the repair service starter kit.

    4. Using a T25 "TORX" socket wrench, install the repair service starter kit with the 2 bolts.

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

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. Apply high-temperature grease to the plunger hook of the magnet starter switch assembly.

    2. B003PSL

      Hang the plunger of the magnet starter switch assembly on the starter pinion 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 terminal C with the nut.

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