STARTER REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. B0073MSC02
      B0073AQ High-temperature Grease

      Apply high-temperature grease to the drive lever set pin as shown in the illustration.

    2. B00733WC02
      *1 Drive Lever Set Pin
      *2 Starter Center Bearing Clutch Sub-assembly

      Install the drive lever set pin to the starter center bearing clutch sub-assembly.

    3. Install the starter center bearing clutch sub-assembly togather with the drive lever set pin to the starter drive housing assembly.

  2. INSTALL PLANETARY GEAR


    1. B0074YVC02
      B0073AQ High-temperature Grease

      Apply high-temperature grease to the 3 planetary gears, 3 planetary gear shafts and starter center bearing clutch sub-assembly.

    2. Install the 3 planetary gears 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. B00765CC09
      *1 Washer
      *a Bearing
      B0073AQ High-temperature Grease

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

    3. B0077QDC02
      B0073AQ High-temperature Grease

      Apply high-temperature grease to the starter armature shaft.

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

    5. B0075OZC02
      *a Snap Ring Pliers

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

      Note


      • Be sure to install the snap ring into the armature shaft groove securely.

      • Do not expand the snap ring excessively.

    6. B0076NRC04
      *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. B0077WR

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

  5. INSTALL STARTER ARMATURE PLATE


    1. B0077DGC08
      *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


    1. B0073QHC06
      *a Rubber
      *b Cutout

      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. B0073XKC05
      *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 REPAIR SERVICE STARTER KIT


    1. B0074C8C01
      *a Hook
      B0073AQ High-temperature Grease

      Apply high-temperature grease to the plunger.

    2. Hang the hook of the plunger on the drive lever set pin.

    3. Apply high-temperature grease to the return spring.

    4. Install the return spring to the plunger.

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

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

    6. Connect the field coil lead wire to the magnet switch with the nut.

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