Starter Reassembly

Apply high-temperature grease to the starter 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 and drive lever set pin together to the starter drive housing.

Apply high-temperature grease to the planet gears and pin parts of the planet shaft.

Install the 3 planetary gears onto the pins of the planet shaft.

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

Hold the starter commutator end frame between aluminum plates in a vise.

NOTICE:

Do not damage the starter commutator end frame.

Apply high-temperature grease to the starter armature assembly as shown in the illustration.

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

Install the plate washer to the starter 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.
   

Check the snap ring length.

1. Using a vernier caliper, measure the snap ring length.
   

   Maximum length:

   5.0 mm (0.197 in.)
   

   If the length is greater than the maximum, replace the snap ring.
   

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

Align the claws of the armature plate with the protrusion inside the starter yoke, and install the starter armature plate.

Align the rubber part on the starter commutator end frame with the cutout of the starter yoke.

Install the starter commutator end frame to the starter yoke.

NOTICE:

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

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

Install the starter yoke with the 2 through bolts.

Torque:

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

Apply high-temperature grease to the plunger and hook.

Hang the plunger hook of the repair service starter kit on the drive lever set pin.

Install the plunger and return spring.

Install the repair service starter kit with the 2 screws.

Torque:

7.5 N*m{76 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}