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. for Type A:


      1. A019LQIE10

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

        Text in Illustration
        A019NE4 High-temperature Grease

      2. Install the 3 planetary gears.

      3. A019O1YE02

        Install the rubber seal.

    2. for Type B:


      1. A019NM1E21

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

        Text in Illustration
        A019NE4 High-temperature Grease

      2. Install the 3 planetary gears.

  2. INSTALL STARTER ARMATURE ASSEMBLY


    1. A019O3EE13

      Apply high-temperature grease to the starter armature shaft.

      Text in Illustration
      A019NE4 High-temperature Grease
    2. A019OGB

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

      Text in Illustration
      A019NE4 High-temperature Grease

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

    4. A019LICE12
      Text in Illustration
      *a 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. A019P8OE31
      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 the snap ring with a new one.

  3. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. A019KE4

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

  4. INSTALL STARTER ARMATURE PLATE


    1. A019ODJE28
      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 COMMUTATOR END FRAME ASSEMBLY


    1. A019O2IE13
      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 commutator end frame assembly to the starter yoke 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.

  6. INSTALL STARTER YOKE ASSEMBLY


    1. A019KY4E13
      Text in Illustration
      *a Cutout
      *b Protrusion

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

    2. A019MXO

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

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

  7. INSTALL MAGNETIC SWITCH ASSEMBLY


    1. for Type A:


      1. A019LRNE03

        Apply high-temperature grease to the plunger and hook.

        Text in Illustration
        A019NE4 High-temperature Grease

      2. Hang the plunger hook of the magnetic switch assembly on the drive lever.

      3. A019P2E

        Install the magnetic switch assembly with the 2 nuts.

        Torque:
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      4. A019MER

        Connect the lead wire to the magnetic switch assembly with the nut.

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

    2. for Type B:


      1. A019PHEE09
        Text in Illustration
        *a Hook
        A019NE4 High-temperature Grease

        Apply high-temperature grease to the plunger.

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

      3. A019PEME07

        Apply high-temperature grease to the return spring.

        Text in Illustration
        A019NE4 High-temperature Grease

      4. Install the plunger and return spring.

      5. A019O85

        Install the magnetic switch assembly with the 2 screws.

        Torque:
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      6. A019MER

        Connect the lead wire to the magnetic switch assembly with the nut.

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