STARTER (for 0.8 kW Type) > REASSEMBLY

for Preparation Click here



1. INSTALL DUST STARTER PROTECTOR

  1. Install the dust starter protector to the starter commutator end frame.



2. INSTALL STARTER HOUSING BEARING


A202509E01

  1. Using SST and a press, insert a new bearing into the drive housing.

    SST
    09820-36010  

    Standard length:
    0.5 to 1.5 mm (from the end of the housing)



3. INSTALL BEARING


A202522E01

  1. Using SST and a press, insert a new bearing into the end of the commutator end frame.

    SST
    09221-25026   (09221-00160)

    Standard length:
    0 mm (from the end of the frame)

  1. Install the clutch and pinion stop nut (inner) onto the armature.



4. INSTALL STARTER CLUTCH SUB-ASSEMBLY

  1. Apply high temperature grease to the clutch bushing, spline and pinion stop nut (inner).



    A104571

  1. Install the clutch and pinion stop nut (inner) onto the armature.

  1. Apply high temperature grease onto the new snap ring and install it onto the armature groove.



    A104572

  1. Compress the snap ring using a vise.



    A104573

  1. While holding the clutch by hand, slightly tap the armature shaft tip with a plastic faced hammer until the pinion stop nut (inner) fits over the snap ring.

  1. Install the pinion stop nut (outer).



5. INSTALL STARTER ARMATURE ASSEMBLY

  1. Clamp the armature shaft in a visa.

    NOTICE:
    Do not clamp the vise too tightly.

  1. Install the armature onto the starter yoke.



6. INSTALL STARTER BRUSH SPRING


A142244

  1. Install the 4 starter brush springs and the starter brush holder.

    NOTICE:
    Do not allow the brush springs to fly off.



7. INSTALL STARTER PLATE


A142270

  1. Install the starter plate.



8. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY


A142242

  1. Install the starter commutator end frame.



9. INSTALL STARTER YOKE ASSEMBLY


    A142271E02

  1. Apply high temperature grease to the contact surfaces between the pinion drive lever and the housing, clutch, and plunger.
    Text in Illustration 
    *1
    		High Temperature Grease



    A142241

  1. Install the yoke and pinion drive lever onto the housing with the 2 through bolts.

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



10. INSTALL MAGNET STARTER SWITCH ASSEMBLY


A142240E04

  1. Apply high temperature grease onto the magnet starter switch plunger.
    Text in Illustration 
    *1
    		Apply High Temperature Grease
    *2
    		Plunger Hook
    *3
    		Pinion Drive Lever

  1. Place the plunger hook in place on the pinion drive lever, and then install the magnet starter switch.



    A198919

  1. Install the 2 nuts.

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



    A198917

  1. Install the lead wire onto the magnet switch terminal with the nut.

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