Starter motor reassembly (RZ4E-TC)

1. Component views

Starter motor

Part name

  1. Nut
  2. Housing
  3. Bearing
  4. Snap ring
  5. Pinion stopper
  6. Dust cover
  7. Magnetic switch
  8. Nut
  9. Pinion and overrunning clutch
  10. Snap ring
  11. Washer
  12. Shift lever
  13. Bearing
  14. Shock absorber
  15. Starter spring
  16. Internal gear
  17. Washer
  18. Clutch shaft
  19. Washer
  20. Planetary gear
  21. Plate
  22. Yoke
  23. M-terminal lead wire
  24. Armature
  25. Brush holder
  26. Bearing
  27. Rear cover
  28. Screw
  29. Through bolt

Tightening torque

1: 7.5 N・m { 0.76 kgf・m / 66.4 lb・in }

8: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

28: 1.5 N・m { 0.15 kgf・m / 13.3 lb・in }

29: 5.5 N・m { 0.56 kgf・m / 48.7 lb・in }

2. Starter motor reassembly

1) Install the following parts to the clutch shaft.

  • Bearing
  • Snap ring
  • Pinion stopper
  • Pinion and overrunning clutch
  • Starter spring
  • Internal gear

Legend

  1. Clutch shaft
  2. Internal gear
  3. Starter spring
  4. Bearing
  5. Snap ring
  6. Pinion and overrunning clutch
  7. Pinion stopper
  8. Snap ring
  9. Bearing

2) Install the planetary gear to the clutch shaft.

Legend

  1. Plate
  2. Planetary gear
  3. Washer
  4. Clutch shaft

3) Install the shift lever to the housing.

Legend

  1. Housing
  2. Shift lever

4) Install the pinion, overrunning clutch, and the clutch shaft as a set to the housing.

5) Install the yoke and plate to the housing.

6) Install the armature to the housing.

Legend

  1. Yoke
  2. Alignment mark
  3. Armature

7) Install the 4 brushes to the brush holder.

8) Prepare the brush holder.

Note

  • If reusing a brush holder, insert the brush into the brush holder with a collar that is the same diameter as the commutator.

Caution

  • Do not damage the brush.

Legend

  1. M-terminal lead wire
  2. Rubber seal
  3. Brush holder
  4. Collar
  5. Holder plate

9) Referring to the diagram, install the brush holder to the commutator while gradually pulling out the collar.

Caution

  • Do not damage the commutator surface.
  • Insert it slowly until the collar comes out completely.

Legend

  1. Yoke
  2. Commutator
  3. Brush holder
  4. Collar

Legend

  1. Yoke
  2. Brush holder
  3. Collar

10) Align the rubber seal with the alignment mark.

Note

  • Firmly push the rubber seal into the alignment mark.

Legend

  1. Yoke
  2. Rubber seal
  3. Brush holder

11) Install the rear cover to the yoke.

Tightening torque: 5.5 N・m { 0.56 kgf・m / 48.7 lb・in } Through bolt

Tightening torque: 1.5 N・m { 0.15 kgf・m / 13.3 lb・in } Screw

Legend

  1. Rear cover
  2. Brush holder

12) Install the dust cover to the housing.

13) Install the magnetic switch to the housing.

Note

  • Align the marking to install.

Tightening torque: 7.5 N・m { 0.76 kgf・m / 66.4 lb・in }

Legend

  1. Housing
  2. Magnetic switch

14) Connect the lead wire of the magnetic switch to the magnetic switch M-terminal.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

1. Pull-in test

Caution

  • Be sure to perform the test with the starter motor fully assembled.
  • The yoke lead wire must not be connected to the M-terminal.
  • To prevent coil seizure, complete the test as quickly as possible.
  • Complete the test within 3 to 5 seconds.

1) Connect the battery negative terminal to the starter motor and M-terminal.

2) Connect the battery positive terminal to the S-terminal.

Note

  • If current is flowing from the battery positive terminal to the S-terminal, the pinion should pop out.

Legend

  1. Positive terminal
  2. S-terminal
  3. M-terminal
  4. Negative terminal

2. Hold-in test

1) Disconnect the M-terminal lead wire from the M-terminal.

Note

  • The pinion should continue popping out.

Legend

  1. Positive terminal
  2. Plunger
  3. S-terminal
  4. M-terminal
  5. Negative terminal

3. Return test

1) Disconnect the battery positive lead of the S-terminal from the S-terminal.

Note

  • The pinion should be returned to the specified position.

Legend

  1. Positive terminal
  2. Plunger
  3. S-terminal
  4. M-terminal
  5. Negative terminal

4. No-load test

1) Referring to the diagram, connect the starter to the battery.

Caution

  • Use a sufficiently thick electric wire, and securely tighten the connection.

Legend

  1. Ammeter
  2. B-terminal
  3. S-terminal
  4. M-terminal
  5. Switch
  6. Voltmeter

2) Close the switch, and check the current and voltage.

Caution

  • If the reading is outside the standard range, disassemble and inspect once again.

Standard: 11.5 V

Standard: 90 A or less

Standard: 2,600 rpm or more

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