STARTER(for 2.0 kW Type) REASSEMBLY

PROCEDURE


  1. INSTALL DUST STARTER PROTECTOR


    1. A005LR2

      Install a new dust starter protector to the starter yoke assembly.

  2. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A005LST

      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. A005JTPE03
      Text in Illustration
      *1 Starter Pinion Drive Lever
      *2 Starter Center Bearing Clutch Sub-assembly

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

    3. Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing.

    4. A005J0G

      Install the rubber seal to the starter drive housing.

  3. INSTALL PLANETARY GEAR


    1. A005JKK

      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.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A005HAE

      Install the starter armature assembly to the starter yoke assembly.

      Note

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

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A005IDW

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

    2. A005HC2

      Install the starter brush holder assembly to the starter armature assembly and push in the 4 brushes as shown in the illustration.

      Note

      Check that the positive (+) lead wires are not grounded.

    3. A005M19E01
      Text in Illustration
      *1 Grommet
      *2 Plate (Positive Side)
      *3 Ground Plate (Negative Side)

      Insert the grommet between the ground plate and plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A005JTV

      Fit the clamp of the brush holder into the starter commutator end frame.

    2. A005JQ5

      Install the starter commutator end frame assembly with the 2 screws.

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

  7. INSTALL STARTER ARMATURE PLATE


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

    2. Install the starter plate so that the cutout is positioned between any of the tabs.

      A005KKIE01
      Text in Illustration
      *1 Tab *2 Cutout

  8. INSTALL STARTER YOKE ASSEMBLY


    1. A005KDTE01
      Text in Illustration
      *1 Tab
      *2 Cutout
      *3 Rubber Seal

      Align the tab of the starter yoke assembly with the cutout located on the starter drive housing.

    2. A005ISC

      Using a long "TORX" socket wrench T25, install the starter yoke assembly with the 2 through bolts.

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

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A005KELE01
      Text in Illustration
      *1 Plunger Hook
      *2 Starter Pinion Drive Lever
      A005GO2 High-temperature grease

      Apply high-temperature grease to the plunger hook.

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

    3. A005I2Q

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A005JZX

      Connect the lead wire to the terminal with the nut.

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

  10. INSTALL STARTER TERMINAL


    1. A005MIK

      Install the starter terminal with the nut.

      Torque:
      15 N*m  { 149 kgf*cm, 11 ft.*lbf }

    2. Close the terminal cap.