STARTER (for 2.2 kW Type Bosch Made) REASSEMBLY


  1. INSTALL PLANET CARRIER SHAFT SUB-ASSEMBLY


    1. Install the 3 damper rubbers and the intermediate sealing to the planet carrier.

    2. A01DV4QE01

      Install the planet carrier shaft to the planet carrier.

    3. Install the washer to the planet carrier shaft.

    4. A01DZ97

      Using a screwdriver and hammer, tap on a new snap ring.

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    1. A01DUYBE01

      Apply MP grease to the spline of the starter clutch sub-assembly and planet carrier shaft.

    2. Install the starter clutch to the planet carrier shaft.

    3. A01DWRQE04

      Apply MP grease to a new snap ring and the pinion stop collar.

    4. Install the pinion stop collar and snap ring.

    5. A01E215E01

      Using a vise, compress the snap ring.

    6. A01DVAHE01

      Using a plastic-faced hammer, lightly tap the planet carrier shaft while holding the outside of the starter clutch sub-assembly by hand until the pinion stop collar and snap ring are as shown in the illustration.

    7. A01DXP6E01

      Apply MP grease to the pinion drive lever.

    8. A01DUZUE02

      Install the starter clutch sub-assembly, pinion drive lever and cover to the starter drive housing.

    9. A01DZGZE01

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

    10. Install the 3 planetary gears to the planet carrier.

  3. INSTALL STARTER ARMATURE ASSEMBLY


    1. A01DWI8E01

      Install the starter armature to the starter yoke.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

    Note

    Do not drop the starter armature assembly.


    1. A01E165E01

      Hold the starter yoke assembly between aluminum plates in a vise.

      Note

      Do not damage the starter yoke.

    2. While compressing the springs, install the starter brush holder to the starter armature.

      Note

      Align the cutout of the starter yoke and the rubber part and install the starter brush holder.

    3. A01E2BQE01

      Install the starter commutator end frame to the starter yoke.

    4. Install the washer to the starter commutator end frame.

    5. A01DWXVE01

      Apply MP grease to the slotted washer and install it.

    6. Install the seal ring.

    7. A01E0N9

      Install the starter commutator end frame cover to the starter commutator end frame with the 2 screws.

      Torque:
      1.8 N*m  { 18 kgf*cm, 16 in.*lbf }

  5. INSTALL STARTER YOKE ASSEMBLY


    1. A01E03ME01

      Fit the 3 claws of the plate into the 3 grooves of the planet carrier to install the plate to the planet carrier.

    2. Install the cover ring to the planet carrier.

    3. A01E2OXE01

      Align the groove of the starter yoke assembly and the starter drive housing cover and install the starter yoke assembly to the starter drive housing.

    4. A01E0SO

      Install the 2 bolts.

      Torque:
      4.8 N*m  { 48 kgf*cm, 42 in.*lbf }

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    1. A01E1IYE01

      Apply MP grease to the hook.

    2. Install the plunger to the pinion drive lever.

    3. A01DV0X

      Install the return spring to the magnet starter switch assembly.

    4. Using a T25 "TORX" socket wrench, install the magnet starter switch assembly with the 3 screws.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    5. A01E2PL

      Connect the lead wire to terminal C with the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }