STARTER(for 1.6 kW Type) REASSEMBLY

PROCEDURE


  1. INSTALL DUST STARTER PROTECTOR


    1. A01VF3Q

      Install the dust starter protector to the starter yoke assembly.

  2. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. A01VFRH

      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
      A01VL3H High-temperature grease
    2. A01VDJ7E03
      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. A01VIZU

      Install the rubber seal to the starter drive housing.

  3. INSTALL PLANETARY GEAR


    1. A01VJ1D

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

      Text in Illustration
      A01VL3H High-temperature grease

    2. Install the 3 planetary gears.

  4. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01VLZD

      Install the starter armature to the starter yoke assembly.

  5. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. A01VDRP

      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. A01VGZ5

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

    3. A01VIL8E01
      Text in Illustration
      *1 Grommet
      *2 Plate (Position Side)
      *3 Ground Plate (Negative Side)

      Insert the grommet between the ground plate and plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. A01VLWO

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

    2. A01VJUS

      Install the starter commutator end frame 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.

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

      A01VLM5E01
      Text in Illustration
      *1 Tab *2 Cutout

  8. INSTALL STARTER YOKE ASSEMBLY


    1. A01VH6AE01
      Text in Illustration
      *1 Tab
      *2 Cutout
      *3 Rubber Seal

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

    2. A01VGLW

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

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

  9. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01VJX5E01

      Apply high-temperature grease to the plunger hook.

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

      Text in Illustration
      *1 Plunger Hook
      *2 Starter Pinion Drive Lever
      A01VL3H High-temperature grease
    3. A01VKT8

      Install the magnet starter switch with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. A01VFXU

      Connect the lead wire to the nut.

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

  10. INSTALL STARTER TERMINAL


    1. A01VJZA

      Install the starter terminal with the nut.

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

    2. Close the terminal cap.