STARTER (for 1.6 kW Type) > REASSEMBLY

for Preparation Click here



1. INSTALL STARTER CENTER BEARING CLUTCH SUB-ASSEMBLY


    A202445E01

  1. Apply high-temperature grease to the starter pinion drive lever which is in contact with the starter pivot part of the starter pinion drive lever.
    Text in Illustration 
    *1
    		High-temperature grease



    A202444E01

  1. Install the starter pinion drive lever into the starter center bearing clutch.
    Text in Illustration 
    *1
    		Starter Pinion Drive Lever
    *2
    		Starter Center Bearing Clutch Sub-Assembly

  1. Install the starter center bearing clutch together with the starter pinion drive lever into the starter drive housing assembly.



    A202443

  1. Install the rubber seal to the starter drive housing.



2. INSTALL STARTER PLANETARY GEAR


    A202441E01

  1. Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
    Text in Illustration 
    *1
    		High-temperature grease

  1. Install the 3 planetary gears.



3. INSTALL STARTER ARMATURE ASSEMBLY


    A202439

  1. Install the starter armature to the starter yoke assembly.



4. INSTALL STARTER BRUSH HOLDER ASSEMBLY


    A211303

  1. Push out the 4 brushes from the brush holder so that they are held in place by the springs, as shown in the illustration.



    A211304

  1. Install the brush holder to the starter armature and push in the 4 brushes, as shown in the illustration.



    A206776E01

  1. Insert the grommet between the ground plate and plate.
    Text in Illustration 
    *1
    		Grommet
    *2
    		Plate (Positive Side)
    *3
    		Ground Plate (Negative Side)



5. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


    A206775

  1. Fit the clamp of the brush holder into the starter commutator end frame.



    A202436

  1. Install the starter commutator end frame with the 2 screws.

    Torque:
    1.5 N*m{ 15 kgf*cm , 13 in.*lbf }



6. INSTALL STARTER ARMATURE PLATE

  1. Install the starter armature plate onto the starter yoke.



  1. Install the starter plate so that the cutout is positioned between the tabs.


    A206777E01


    Text in Illustration 
    *1
    		Tab
    		*2
    		Cutout



7. INSTALL STARTER YOKE ASSEMBLY


    A202446E01

  1. Align the tab of the starter yoke with the cutout located on the starter drive housing assembly.
    Text in Illustration 
    *1
    		Tab
    *2
    		Cutout
    *3
    		Rubber Seal



    A202434

  1. Using "TORX" socket wrench T25, install the starter yoke assembly with the 2 through bolts.

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



8. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    A202433E01

  1. Apply high-temperature grease to the hook.

  1. Connect the plunger hook to the starter pinion drive lever.
    Text in Illustration 
    *1
    		Plunger Hook
    *2
    		Starter Pinion Drive Lever
    *3
    		High-temperature grease



    A202432

  1. Install the magnet starter switch with the 2 nuts.

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



    A198945

  1. Connect the lead wire to the nut.

    Torque:
    10 N*m{ 102 kgf*cm , 7.4 ft.*lbf }



9. INSTALL STARTER TERMINAL


    A202431

  1. Install the starter terminal with the nut.

    Torque:
    10 N*m{ 102 kgf*cm , 7.4 ft.*lbf }

  1. Close the terminal cap.