Reassembly

Hint:

Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.

1. 1
   Install planetary gear
2. 2
   Apply grease to the planetary gears and pin parts of the planetary shaft.
3. 3
   Install the 3 planetary gears.

   

2. Install starter armature assembly

1. 1
   Apply grease to the plate washer and the armature shaft.
2. 2
   Install the starter armature to the starter commutator end frame.
3. 3
   Using snap ring pliers, install the plate washer and a new snap ring.
4. 4
   Using a vernier caliper, measure length of the snap ring.

Maximum length: 5.0 Mm (0.197 In.)

If the length is greater than the maximum, replace it with a new snap ring.

3. Install starter commutator end frame cover

1. 1
   Install the end frame cover to the commutator end frame.
2. 2
   Install starter armature plate

   

1. 1
   Insert the armature plate to the starter yoke.
2. 2
   Align the keyway of the starter plate with the key inside the starter yoke, and install the starter plate.
3. 3
   Install starter commutator end frame assembly

   

1. 1
   Align the rubber of the end frame with the cutout of the starter yoke.
2. 2
   Install the end frame to the starter yoke.
3. 3
   Install starter yoke assembly
4. 4
   Align the protrusion of the starter yoke with the cutout of the starter drive housing.

   

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

Torque: 5.9 N*m (60 kgf*cm, 52 in.*Lbf)

7. Install magnetic switch assembly

1. 1
   Apply grease to the plunger and the hook.
2. 2
   Hang the plunger hook of the magnetic switch to the drive lever.
3. 3
   Install the plunger and return spring.

   

4. Install the magnetic switch with the 2 screws.

Torque: 7.5 N*m (76 kgf*cm, 66 in.*Lbf)

5. Connect the lead wire to the magnetic switch with the nut.

Torque: 10 n*m (102 kgf*cm, 7 ft.*Lbf)