STARTER(for 2.0 kW Type) REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE


  1. INSTALL DUST STARTER PROTECTOR

    A005LNM

    1. Install a new dust starter protector to the starter commutator end frame.

  2. INSTALL PLANETARY GEAR


    1. A005MGV

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

      Text in Illustration
      A005GO2 High-temperature grease

    2. Install the 3 planetary gears.

  3. INSTALL STARTER ARMATURE PLATE


    1. A005IE8E08
      Text in Illustration
      *1 Tab
      *2 Projection

      Insert the starter armature plate to the starter center bearing clutch.

    2. Check that the tab of the starter armature plate fits over the projection of the starter center bearing clutch sub-assembly.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A005GZJ

      Install the starter armature to the starter yoke.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A005LK8E01
      Text in Illustration
      *1 Tab
      *2 Cutout

      Align the tab of the starter center bearing clutch with the cutout of the starter yoke, and install the starter yoke.

  6. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Install the starter brush holder assembly.

    2. A005LI2

      Using a screwdriver, hold the brush spring back and connect the brush into the brush holder.

    3. Connect the 4 brushes.

  7. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A005GWK

      Align the starter commutator end frame rubber with the groove.

    2. A005M1J

      Install the starter commutator end frame with the 2 screws.

      Torque:
      3.8 N*m  { 39 kgf*cm, 33 in.*lbf }

  8. INSTALL STARTER DRIVE HOUSING ASSEMBLY


    1. A005LW2

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

      Text in Illustration
      A005GO2 High-temperature grease
    2. A005IZ9

      Install the starter pinion drive lever to the starter center bearing clutch.

    3. A005GZZ

      Align the claw of the starter center bearing clutch with the groove inside the starter drive housing, and install the starter center bearing clutch to the starter drive housing.

    4. A005HX0

      Using long "TORX" socket wrench T30, install the starter drive housing with the 2 through bolts.

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

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A005GNVE01

      Apply high-temperature grease to the hook.

    2. Connect the plunger hook to the starter pinion drive lever.

      Text in Illustration
      *1 Plunger Hook
      *2 Starter Pinion Drive Lever
      A005GO2 High-temperature grease
    3. A005LD7

      Install the magnet starter switch with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A005LTT

      Connect the lead wire to the terminal with the nut.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  10. INSTALL STARTER TERMINAL


    1. A005KBE

      Install the starter terminal with the nut.

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

    2. Close the terminal cap.