STARTER REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

Use high-temperature grease to lubricate the bearings and sliding parts when assembling the starter.

PROCEDURE

  1. INSTALL PLANETARY CARRIER SHAFT SUB-ASSEMBLY

    1. Install the planetary carrier shaft to the planetary carrier.

    2. Install the washer to the planetary carrier shaft.

    3. A105363

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

  2. INSTALL STARTER CLUTCH SUB-ASSEMBLY

    1. U121190

      Apply high-temperature grease to the splines of the starter clutch and planetary carrier shaft.

      Table 1. Text in Illustration
      V100135

      High-temperature Grease

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

    3. A104907E08

      Install the pinion stop collar and a new snap ring as shown in the illustration.

      Table 2. Text in Illustration

      *1

      Snap Ring

      *2

      Pinion Stop Collar
    4. A104906E06

      Using a vise, compress the snap ring between aluminum plates.

      Table 3. Text in Illustration

      *1

      Planetary Carrier Shaft

      *2

      Snap Ring
    5. A122041E05

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

      Table 4. Text in Illustration

      *1

      Snap Ring

      *2

      Pinion Stop Collar

    6. Install the center bearing clutch, pinion drive lever and drive housing cover to the drive housing.

    7. U121313

      Apply high-temperature grease to the planetary carrier.

      Table 5. Text in Illustration
      V100135

      High-temperature Grease

    8. Install the 3 planetary gears to the planetary carrier.

  3. INSTALL STARTER ARMATURE ASSEMBLY

    1. Install the starter armature to the starter yoke.

  4. INSTALL STARTER BRUSH HOLDER ASSEMBLY

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

      Note:

      Do not damage the starter yoke.

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

      Note:

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

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

    4. Install the washer to the commutator end frame.

    5. Apply high-temperature grease to the slotted washer.

    6. Install the slotted washer.

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

      1.4 N*m

      14 kgf*cm

      12 in.*lbf

  5. INSTALL STARTER YOKE ASSEMBLY

    1. A165827

      Install the armature plate to the planetary carrier as shown in the illustration.

    2. A264703E02

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

      Table 6. Text in Illustration

      *1

      Drive Housing Cover

      *2

      Groove

    3. Install the starter yoke to the drive housing with the 2 bolts.

      4.8 N*m

      49 kgf*cm

      42 in.*lbf

  6. INSTALL MAGNET STARTER SWITCH ASSEMBLY

    1. U121312E02

      Apply high-temperature grease to the hook of the plunger.

      Table 7. Text in Illustration

      *1

      Pinion Drive Lever

      *2

      Plunger
      V100135

      High-temperature Grease

    2. Install the plunger to the pinion drive lever.

    3. Install the return spring to the magnet starter switch.

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

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

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

      8.0 N*m

      82 kgf*cm

      71 in.*lbf