STARTER REASSEMBLY

Tech Tips

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

  1. INSTALL PLANETARY GEAR

    1. Apply grease to the planetary gears and pin parts of the planetary shaft.

      A011RCZE16
      Text in Illustration
      A011T1X High-temperature grease

    2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY

    1. Apply grease to the armature shaft.

      A011S2CE10
      Text in Illustration
      A011T1X High-temperature grease

    2. Apply high-temperature grease to the plate washer and bearing, as shown in the illustration.

      A011R30E04
      Text in Illustration
      A011T1X High-temperature grease

    3. Install the starter armature to the starter commutator end frame.

    4. Using snap ring pliers, install the plate washer and a new snap ring.

      A011RBEE12
      Text in Illustration
      *a Snap Ring Pliers

      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.

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

      A011QV0E33
      Text in Illustration
      *a Length
      Maximum length
      5.0 mm (0.196 in.)

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

  3. INSTALL STARTER COMMUTATOR END FRAME COVER

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

      A011R1H

  4. INSTALL STARTER ARMATURE PLATE

    1. Insert the starter armature plate to the starter yoke.

      A011UTRE28
      Text in Illustration
      *a Keyway
      *b Key

    2. Align the keyway of the starter armature plate with the key inside the starter yoke, and install the starter armature plate.

  5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY

    1. Align the rubber of the end frame with the cutout of the starter yoke.

      A011U0FE15
      Text in Illustration
      *a Cutout
      *b Rubber

    2. Install the end frame to the starter yoke.

      Note

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

  6. INSTALL STARTER YOKE ASSEMBLY

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

      A011SNLE14
      Text in Illustration
      *a Cutout
      *b Protrusion

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

      A011TNI
      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  7. INSTALL REPAIR SERVICE STARTER KIT

    1. Apply grease to the plunger and the hook.

      A011T0NE06
      Text in Illustration
      A011T1X High-temperature grease

    2. Hang the plunger hook of the magnetic switch to the drive lever.

    3. Install the plunger and return spring.

    4. Install the magnetic switch with the 2 screws.

      A011UC0
      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

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

      A011S8D
      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }