Assembly Of Starter

HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

1. PLACE ARMATURE INTO FIELD FRAME

Apply grease to the armature bearings, and insert the armature into the field frame.

2. INSTALL BRUSH HOLDER

(a) Place the brush holder in position on the armature.

(b) Using a screwdriver, hold the Jbrush spring back, and connect the brush into the brush holder. Connect the four brushes.

NOTICE: Check that positive ( + ) lead wires are not grounded.

Place a new O-ring in position on the field frame.

(d) Install the end cover with two new O-rings (1.4 kW and 1.6 kW types) and the two screws.

3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE

(a) Apply grease to the steel ball.

(b) Insert the steel ball into the clutch shaft hole.

4. INSTALL GEAR(S)

(a) Apply grease to the return spring.

(b) Insert the return spring into the magnetic switch hole.

(c) Place the following parts in position on the starter housing:

(1) Idler gear

(2) Bearing

1.4 kW (Conventional) and

1.4 kW (Conventional) and

(1.4 kW (Conventional) and 1.6 kW Types)

(1) Idler gear

(2) Bearing

(3) Pinion gear

(d) Assemble the starter housing and magnetic switch with the two screws.

5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY

Place a new O-ring in position on the field frame.

(b) Align the protrusion of the field frame with the cutout of the magnetic switch.

(c) Install the field frame and armature assembly with the two through bolts.

(d) Connect the lead wire to terminal C, and install the nut.

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