STARTER (for 1.0 kW Type) REASSEMBLY


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A0119YB

      Apply high temperature grease to the bushing and spline of the starter clutch and stop collar.

    2. Place the starter clutch and stop collar on the planet carrier shaft.

    3. Apply high temperature grease to a new snap ring and install it to the planet carrier shaft groove.

    4. A0117H8

      Using a vise, compress the snap ring.

    5. A0118K2

      Hold the starter clutch, tap the planet carrier shaft, and install the starter pinion stop collar onto the snap ring with a plastic-faced hammer.

    6. A0117MPE04
      Text in Illustration
      *1 High-temperature grease

      Apply high temperature grease to the drive lever which is in contact with the starter pivot part of the drive lever.

    7. Install the drive lever to the starter clutch.

    8. A011A7WE01
      Text in Illustration
      *1 Alignment mark
      *2 Cutout

      Install the shock absorber by matching the drive housing cutout with the shock absorber alignment mark.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. Install the starter armature to the starter yoke.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01174O

      Install the brush holder.

    2. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the 4 brushes.

    3. Apply turbine oil to the bearing of the end frame.

  4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A011AOK

      Install the end frame with the 2 screws.

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

      Note

      To avoid interference between the brush holder and the dust starter protector, tilt the commutator end frame while installing it.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A0116X1E01
      Text in Illustration
      *1 Cutout
      *2 Projection

      Align the cutout of the starter yoke with the projection of the planet carrier shaft sub-assembly.

    2. A011ASN

      Install the starter yoke with the 2 through bolts.

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

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A0118C3E02
      Text in Illustration
      *1 High-temperature grease
      *2 Plunger
      *3 Pinion Drive Lever

      Apply high temperature grease to the starter magnet switch plunger.

    2. Install the starter magnet switch by hanging the starter magnet switch plunger on the upper area of the pinion drive lever.

    3. A0117YS

      Install the magnet starter switch with the 2 nuts.

      Torque:
      8.3 N*m  { 85 kgf*cm, 74 in.*lbf }
    4. A01186K

      Connect the lead wire to the terminal with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }