STARTER (for 2.0 kW Type) REASSEMBLY


  1. INSTALL STARTER ARMATURE ASSEMBLY

    Install the starter armature to the starter yoke.

  2. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    1. Place the brush holder assembly on the starter yoke.

    2. B007PUQ

      Using a screwdriver, install the 4 brushes.

      Note

      Check that the positive (+) lead wires are not grounded.

    3. Place a new O-ring in position on the commutator end frame.

    4. Install the new dust protector to the commutator end frame.

    5. B007RDH

      Install the commutator end frame with the 2 screws.

      Torque:
      3.8 N*m  { 39 kgf*cm, 34 in.*lbf }

  3. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. B007ONBE02

      Apply grease to the steel ball and install it onto the starter clutch.

    2. Apply grease to the starter clutch, and install it onto the starter drive housing.

    3. Apply grease to the magnet switch return spring and install it onto the starter clutch.

    4. Apply grease to the clutch roller and install it onto the retainer.

    5. Apply grease to the retainer and install it onto the starter idle pinion.

    6. Apply grease to the starter idle pinion and install it onto the starter drive housing.

    7. Apply grease to the pinion gear and install it onto the starter drive housing.

    8. B007OLC

      Install the starter switch with the 2 screws.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

  4. INSTALL STARTER YOKE ASSEMBLY


    1. Place a new O-ring in position on the starter yoke.

    2. B007OL8E01

      Install the starter yoke to the starter switch.

      Tech Tips

      Align the claw of the starter yoke with the groove of the starter switch.

    3. B007VVX

      Tighten the 2 through bolts.

      Torque:
      9.3 N*m  { 95 kgf*cm, 82 in.*lbf }

    4. Connect the lead wire to terminal C with the nut.

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