STARTER REASSEMBLY

Tech Tips

Use high-temperature grease to lubricate the bearings, planetary gears and return spring when assembling the starter assembly.


  1. INSTALL PLANETARY GEAR


    1. A01ETS2E20

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

      Text in Illustration
      A01EUL1 High-temperature grease

    2. Install the 3 planetary gears to the repair service starter kit.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01ESVHE12

      Apply high-temperature grease to the armature shaft.

      Text in Illustration
      A01EUL1 High-temperature grease
    2. A01EUNIE07

      Apply high-temperature grease to the washer and bearing as shown in the illustration.

      Text in Illustration
      A01EUL1 High-temperature grease

    3. Install the starter armature assembly to the starter commutator end frame assembly.

    4. A01EWSNE10
      Text in Illustration
      *1 Snap Ring Pliers

      Using snap ring pliers, install the washer and a new snap ring.

      Note


      • Be sure to install the snap ring in the armature shaft groove securely.

      • Be sure to properly install the snap ring because it expands easily.

    5. A01EYEFE33
      Text in Illustration
      *a Length

      Using a vernier caliper, measure the length of the snap ring.

      Maximum length
      5.0 mm (0.197 in.)

      If the length is greater than the maximum, replace it with a new snap ring.

  3. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A01ETKL

      Install the starter commutator end frame cover to the starter commutator end frame assembly.

  4. INSTALL STARTER ARMATURE PLATE


    1. A01EYVTE28
      Text in Illustration
      *a Keyway
      *b Key

      Insert the starter armature plate to the starter yoke assembly.

    2. Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01EXLGE15
      Text in Illustration
      *a Cutout
      *b Rubber

      Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly.

    2. Install the starter yoke assembly to the starter commutator end frame assembly.

      Note

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

    3. A01ETJEE14
      Text in Illustration
      *a Cutout
      *b Protrusion

      Align the protrusion of the starter yoke assembly with the cutout of the repair service starter kit.

    4. A01EWL7

      Install the starter yoke assembly with the 2 through-bolts.

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

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01EXZVE09
      Text in Illustration
      *a Hook
      A01EUL1 High-temperature grease

      Apply high-temperature grease to the plunger.

    2. Hang the hook of the plunger on the drive lever.

    3. A01EXNRE07

      Apply high-temperature grease to the return spring.

      Text in Illustration
      A01EUL1 High-temperature grease

    4. Install the plunger and return spring to the repair service starter kit.

    5. Install the magnet switch.

    6. A01ETW3

      While holding the magnet switch, install the 2 screws to the repair service starter kit.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    7. A01EYPS

      Connect the lead wire to the magnet switch with the nut.

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