Reassembly
1AR-FE STARTING: STARTER: REASSEMBLY
HINT
Use high-temperature grease to lubricate the bearing and gears when assembling the starter.
1. INSTALL PLANETARY GEAR
(a) Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft.
Text in Illustration
(b) Install the 3 planetary gears.
2. INSTALL RUBBER SEAL
(a) Install the rubber seal.
3. INSTALL STARTER ARMATURE ASSEMBLY
(a) Apply high-temperature grease to the washer and armature shaft.
Text in Illustration
(b) Apply high-temperature grease to the plate washer and a new snap ring.
Text in Illustration
NOTICE:
* Be sure to install the snap ring in the armature shaft groove securely.
* Be sure to properly install the snap ring because it expands easily.
(c) Install the starter armature assembly to the starter commutator end frame assembly.
(d) Using snap ring pliers, install the plate washer and a new snap ring.
Text in Illustration
(e) Using a vernier caliper, measure the length of the snap ring.
Text in Illustration
Maximum length:
5.0 mm (0.197 in.)
If the length is greater than the maximum, replace it with a new snap ring.
4. INSTALL STARTER COMMUTATOR END FRAME COVER
(a) Install the starter commutator end frame cover to the starter commutator end frame assembly.
5. INSTALL STARTER ARMATURE PLATE
(a) Insert the starter armature plate to the starter yoke assembly.
Text in Illustration
(b) Align the keyway of the starter armature plate with the key inside the starter yoke assembly, and install the starter armature plate.
6. INSTALL STARTER COMMUTATOR END FRAME ASSEMBLY
(a) Align the rubber of the starter commutator end frame assembly with the cutout of the starter yoke assembly.
Text in Illustration
(b) Install the starter commutator end frame to the starter yoke assembly.
NOTICE:
The magnet of the starter yoke assembly may attract the starter armature assembly when the starter commutator end frame assembly is installed, causing the magnet to break.
7. INSTALL STARTER YOKE ASSEMBLY
(a) Align the protrusion of the starter yoke assembly with the cutout of the repair service starter kit.
Text in Illustration
(b) Install the starter yoke assembly with the 2 through bolts.
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
8. INSTALL MAGNETIC SWITCH ASSEMBLY
(a) Apply high-temperature grease to the plunger and the pinion drive lever.
Text in Illustration
(b) Install the magnetic switch assembly by hanging the magnet starter switch plunger on the upper area of the pinion drive lever.
(c) Install the magnetic switch assembly with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(d) Connect the lead wire to the terminal C with the nut.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)