STARTER REASSEMBLY

PROCEDURE


  1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A005IEK

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

      Text in Illustration
      A005GO2 High-temperature Grease

    2. Place the starter clutch and stop collar on the planetary shaft.

    3. Apply high-temperature grease to a new snap ring, and install it onto the shock absorber groove.

    4. A005KTP

      Using a vise, compress the snap ring.

    5. A005IZ1

      While holding the starter clutch sub-assembly, tap the shock absorber and install the stop collar onto the snap ring with a plastic-faced hammer.

    6. A005HYAE03
      Text in Illustration
      *1 Starter Pinion Drive Lever
      *2 Starter Clutch Sub-assembly
      A005GO2 High-temperature Grease

      Apply high-temperature grease to the parts of the starter pinion drive lever that contact the pivot part of the starter housing.

    7. Install the starter pinion drive lever onto the starter clutch sub-assembly.

    8. A005JBBE03
      Text in Illustration
      *1 Starter Housing
      *2 Cutout
      *3 Protrusion
      *4 Shock Absorber

      Align the protrusion of the shock absorber with the cutout of the starter housing and install it.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A005LOEE04
      Text in Illustration
      *1 Starter Armature Assembly
      *2 Starter Yoke Assembly

      Install the starter armature assembly onto the starter yoke assembly.

  3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Install the starter brush holder assembly.

    2. A005IDV

      Using a screwdriver, hold the brush spring back, and install the 4 brushes into the brush holder.

    3. Apply spindle oil to the bearing of the commutator end frame.

    4. A005HUP

      Install the commutator end frame with 2 new screws.

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

      Note

      To avoid interference between the brush holder and the dust protector, push the commutator end frame away at an angle.

  4. INSTALL STARTER YOKE ASSEMBLY


    1. A005KWTE03
      Text in Illustration
      *1 Shock Absorber
      *a Protrusion
      *b Cutout

      Align the cutout of the field frame with the protrusion of the shock absorber.

    2. A005J3T

      Install the field frame and the starter armature assembly with the 2 through bolts.

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

  5. INSTALL MAGNET STARTER SWITCH ASSEMBLY

    A005HMW

    1. Hang the plunger hook of the magnet starter switch assembly in the starter pinion drive lever from the upper side.

    2. A005JFG

      Install the magnet starter switch assembly with the 2 nuts.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }
    3. A005LIW

      Connect the lead wire to the terminal with the nut.

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