STARTER(for 2.0 kW Type) REASSEMBLY

PROCEDURE

1. INSTALL STARTER CLUTCH SUB-ASSEMBLY

   
   

   1. Apply high-temperature grease to the steel ball and install it to the hole of the starter clutch shaft.

   2. 

      Apply high-temperature grease to the return spring, retainer, idle gear pinion and starter crutch sub-assembly.

   3. Install the return spring to the starter clutch sub-assembly.

   4. Install the starter clutch sub-assembly, clutch roller, retainer and starter idle gear to the starter drive housing assembly.

2. INSTALL MAGNET STARTER SWITCH ASSEMBLY

   
   

   1. Install the magnet starter switch assembly to the starter drive housing assembly with the 2 screws.

      Torque:

      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

3. INSTALL STARTER ARMATURE ASSEMBLY

   
   

   1. Apply high-temperature grease to the bearings and install the starter armature assembly to the starter yoke assembly.

4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

   
   

   1. Install the starter brush holder assembly to the starter yoke assembly.

   2. Install the 4 starter brushes to the starter brush holder assembly.

      
      

      1. Using a screwdriver, pull back the spring.

      2. Install the starter brush to the starter brush holder assembly.

         Note

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

   3. Install a new O-ring to the groove of the field frame.

   4. Install the commutator end frame with the 2 screws.

      Torque:

      3.8 N*m  { 39 kgf*cm, 34 in.*lbf }

5. INSTALL STARTER YOKE ASSEMBLY

   
   

   1. Install a new O-ring to the groove of the starter yoke assembly.

   2. 

      *a	Key
      *b	Groove

      Align the key of the starter yoke assembly with the groove of the magnet starter switch assembly.

   3. Install the 2 bolts.

      Torque:

      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

   4. Attach the wire harness clamp and connect the lead wire to terminal C with the nut.

      Torque:

      5.9 N*m  { 60 kgf*cm, 52 in.*lbf }