STARTER (for 1.6 kW Type) REASSEMBLY


  1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    1. B007UO2E01

      Install the drive lever set pin to the starter center bearing clutch sub-assembly

    2. Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.

  2. INSTALL PLANET GEAR


    1. B007T07

      Apply grease to the planet gears and pin parts of the planet shaft.

    2. Install the 3 planet gears.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. Apply grease to the plate washer and armature shaft.

    2. Install the armature shaft to the starter commutator end frame.

    3. B007P01E01

      Using snap ring pliers, install the plate 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 easily expands.

    4. B007TJSE01

      Using vernier calipers, measure the snap ring.

      Maximum length
      5.0 mm (0.197 in.)

      If the length is greater than the maximum, replace the snap ring.

  4. INSTALL STARTER COMMUTATOR END FRAME COVER


    1. B007RA6E01

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

  5. INSTALL STARTER ARMATURE PLATE


    1. B007TAEE01

      Align the claw of the armature plate with the groove inside the starter yoke, and install the starter armature plate.

  6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    1. B007W36E01

      Align the starter commutator end frame rubber with the groove of the starter yoke.

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

      Note

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

  7. INSTALL STARTER YOKE ASSEMBLY


    1. B007SABE01

      Align the claw of the starter yoke assembly with the groove inside the starter drive housing.

    2. B007W5F

      Install the starter yoke assembly with the 2 bolts.

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

  8. INSTALL REPAIR SERVICE STARTER KIT


    1. Apply grease to the plunger and hook.

    2. B007S16

      Hang the plunger hook of the repair service starter kit to the drive lever.

    3. B007U81

      Install the repair service starter kit with the 2 screws.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    4. B007P95

      Connect the lead wire to terminal C with the nut.

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