STARTER (w/o Stop And Start System) > REASSEMBLY

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1. INSTALL STARTER CLUTCH SUB-ASSEMBLY


    A158889

  1. Apply grease to the bushing and spline of the starter clutch and stop collar.

  1. Place the starter clutch and stop collar on the planet carrier shaft.

  1. Apply grease to a new snap ring and install it to the planet carrier shaft groove.



    A033608

  1. Using a vise, compress the snap ring.



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  1. Hold the starter clutch, tap the planet carrier shaft, and install the starter pinion stop collar onto the snap ring with a plastic-faced hammer.



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  1. Apply grease to the part of the drive lever which is in contact with the starter pivot.
    Text in Illustration 
    *1
    		Grease

  1. Install the drive lever to the starter clutch.



    A156366E04

  1. Align the tab of the shock absorber with the cutout of the drive housing, and install the shock absorber.
    Text in Illustration 
    *a
    		Cutout
    *b
    		Tab



2. INSTALL STARTER ARMATURE ASSEMBLY

  1. Install the starter armature to the starter yoke.



3. INSTALL STARTER BRUSH HOLDER ASSEMBLY


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  1. Install the brush holder.

  1. Using a screwdriver, hold the brush spring back and connect the brush into the brush holder. Connect the 4 brushes.

  1. Apply turbine oil to the bearing of the end frame.



4. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


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  1. Install the end frame with the 2 screws.

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

    NOTICE:
    To avoid interference between the brush holder and the dust starter protector, tilt the commutator end frame while installing it.



5. INSTALL STARTER YOKE ASSEMBLY


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  1. Align the cutout of the starter yoke with the projection of the planet carrier shaft sub-assembly.
    Text in Illustration 
    *a
    		Cutout
    *b
    		Projection



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  1. Install the starter yoke with the 2 through bolts.

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



6. INSTALL MAGNET STARTER SWITCH ASSEMBLY


    A203473E01

  1. Install the magnet starter switch by hanging the magnet starter switch plunger on the upper area of the pinion drive lever.
    Text in Illustration 
    *1
    		Plunger
    *2
    		Pinion Drive Lever



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

    Torque:
    8.3 N*m{ 85 kgf*cm , 73 in.*lbf }



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  1. Connect the lead wire to the terminal with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }