Starter Reassembly

Apply high-temperature grease to the drive lever set pin, as shown in the illustration.

Install the drive lever set pin to the starter center bearing clutch sub-assembly.

Install the starter center bearing clutch with the drive lever set pin to the starter drive housing.

Apply high-temperature grease to the planetary gears and pin parts of the planetary shaft, as shown in the illustration.

Install the 3 planetary gears.

Apply high-temperature grease to the plate washer, new snap ring and bearing, as shown in the illustration.

Install the armature assembly to the starter commutator end frame assembly.

Install the plate washer to the armature shaft.

Using snap ring pliers, install the snap ring.

NOTICE:

1. Be sure to install the snap ring in the armature shaft groove securely.
   
2. Be sure to properly install the snap ring because it easily expands.
   

Using vernier calipers, measure the snap ring.

Maximum length:

5.0 mm (0.197 in.)

Install the starter commutator end frame cover to the starter commutator end frame assembly.

Align the claw of the armature plate with the groove inside the starter yoke assembly, and install the starter armature plate.

Align the starter commutator end frame rubber with the groove of the starter yoke assembly.

Install the starter commutator end frame to the starter yoke assembly.

NOTICE:

The magnet of the starter yoke assembly may attract the starter armature when the starter commutator end frame assembly is installed, causing magnet breakage.

Align the claw of the starter yoke assembly with the groove inside the starter drive housing.

Install the starter yoke assembly with the 2 bolts.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Apply high-temperature grease to the plunger and hook, as shown in the illustration.

Hang the plunger hook of the repair service starter kit to the drive lever.

Install the plunger and the return spring.

Install the repair service starter kit with the 2 screws.

Torque:

7.5 N*m{77 kgf*cm, 66 in.*lbf}

Connect the lead wire to terminal C with the nut.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}