STARTER (for 1.6 kW Type) REASSEMBLY

Tech Tips

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


  1. INSTALL PLANETARY GEAR


    1. A01CG0TE01

      Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.

    2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01CCTIE02
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Armature Assembly

      Install the starter armature onto the starter yoke.

      Note

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

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Install the starter brush holder assembly.


      1. A01CFMCE02

        Push out the 4 brushes from the brush holder so that they are held in place by the springs, as shown in the illustration.

      2. A01CCUQ

        Install the brush holder to the starter armature and push in the 4 brushes.

      3. A01CDN0E07
        Text in Illustration
        *1 Grommet
        *2 Negative (-) pole
        *3 Positive (+) pole

        Insert the grommet between the positive (+) pole and negative (-) pole.

  4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01CFX9E03
      Text in Illustration
      *1 Starter Yoke Assembly
      *2 Starter Commutator End Frame Assembly

      Fit the starter commutator end frame assembly onto the clamp of the brush holder.

    2. A01CDBH

      Install the commutator end frame with the 2 screws.

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

  5. INSTALL STARTER ARMATURE PLATE


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

    2. Install the starter armature plate so that the keyway is positioned between the keys.

      A01CF7LE03
      Text in Illustration
      *1 Key - -

  6. INSTALL STARTER YOKE ASSEMBLY


    1. A01CED8E02
      Text in Illustration
      *1 Key
      *2 Keyway

      Align the key of the starter yoke with the keyway located on the starter drive housing assembly.

    2. A01CFZM

      Using a T25 "TORX" socket wrench, install the drive housing with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  7. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. Apply high-temperature grease to the plunger hook.

    2. A01CESU

      Hang the plunger of the magnet starter switch assembly into the drive lever from the upper side.

    3. A01CAWX

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    4. A01CCNF

      Connect the lead wire to the magnet starter switch, then fasten it with the nut.

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