Disassembly and Reassembly
DISASSEMBLY1. REMOVE FIELD FRAME WITH ARMATURE FROM MAGNETIC SWITCH ASSEMBLY
a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.
b. Remove the 2 through bolts.
c. Remove the 2 screws and end cover from the field frame.
d. Remove the ring from the field frame.
e. Using a screwdriver, hold the spring tank back and disconnect the brush from the brush holder. Disconnect the 4 brushes and remove the brush holder.
f. Pull out the field frame from the magnetic switch assembly.
g. Remove the O-ring.
2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Remove the 2 bolts.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
b. Remove these parts from the magnetic switch assembly:
1. Starter housing
2. Idler gear
3. Bearing
4. Clutch assembly
5. Return spring
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.
4. REMOVE ARMATURE FROM MAGNETIC SWITCH ASSEMBLY
a. 1ZZ-FE
Remove the armature from the magnetic switch assembly.
b. 2ZZ-GE:
Using a press, remove the armature from the magnetic switch assembly.
REASSEMBLY
HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.
1. INSTALL ARMATURE TO MAGNETIC SWITCH ASSEMBLY
a. 2ZZ-GE:
Rotating the ring of the front bearing, set it properly so that the projection of the ring is positioned in the narrowest part.
b. Apply grease to the armature bearings.
c. 1ZZ-FE:
Install the armature to the magnetic switch assembly.
d. 2ZZ-GE:
Using a press, install the armature to the magnetic switch assembly.
2. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE
a. Apply grease to the steel ball.
b. Insert the steel ball into the clutch shaft hole.
3. INSTALL STARTER HOUSING, CLUTCH ASSEMBLY AND GEARS
a. Apply grease to the return spring.
b. Insert the return spring into the magnetic switch hole.
c. Place these parts on the starter housing:
1. New O-ring
2. Starter clutch assembly
3. Idler gear
4. Bearing
d. Install the starter housing to the magnetic switch with the 2 screws.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
4. INSTALL FIELD FRAME
a. Install a new O-ring to the groove of the filed frame.
b. Align the protrusion of the field frame with the groove of the magnetic switch, and install the field frame.
5. INSTALL BRUSH HOLDER
a. Place the brush holder on the field frame.
b. Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.
NOTE: Check that the positive (+) lead wires are not grounded.
6. INSTALL END COVER
a. Install a new O-ring to the groove of the field frame.
b. Install the end cover to the field frame with the 2 screws.
Torque: 3.8 N.m (39 kgf.cm, 34 in.lbf)
c. Install the field frame and armature assembly with the 2 through bolts.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
d. Connect the lead wire to terminal C with the nut.
Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)
7. INSTALL NEW DUST PROTECTOR
REPLACEMENT
1. INSPECT BEARING
Turn the bearing by hand while applying inward force.
If resistance is felt or if the sticks, replace the bearing.
2. REPLACE BEARINGS
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new front bearing.
SST 09820-00031
c. Using a press, press in a new rear bearing.
3. REMOVE MAGNETIC SWITCH END COVER
a. Remove the 3 bolts, end cover, gasket and plunger.
b. Inspect the contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove the terminal kit parts.
1. Using SST, loosen the terminal nuts.
SST 09810-38140
2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, and terminal insulator (inside).
d. Temporarily install a new terminal 30 kit parts.
1. Install a terminal insulator (inside).
NOTE: Be careful to install the terminal insulator in the correct direction.
2. Install a contact plate.
3. Install a terminal bolt.
4. Install a O-ring.
5. Install a packing and terminal insulator (outside). Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Install a wave washer.
7. Install a terminal nut.
e. Temporarily install new terminal C kit parts.
1. Install a terminal insulator (inside).
2. Install a contact plate.
3. Install a terminal bolt.
4. Install a O-ring.
5. Install a terminal insulator (outside).
6. Install a wave washer.
7. Install a terminal nut.
NOTE: Be careful to install the terminal insulator (inside) in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nut.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTE:
Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied.
Gauge Pressure:
If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N.m (173 kgf.cm, 12 ft.lbf)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover.
Install the plunger, new gasket, end cover with the 3 bolts.
Torque: 2.5 N.m (26 kgf.cm, 23 in.lbf)