Starting System & Charging System (H4SO): Starter: Assembly

Install the armature to the yoke.

Fig 1: Removing Armature From Yoke
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Install the brush holder assembly to the armature.
NOTE: Expand the brush with your fingers while taking care not to scratch it.

Fig 2: Identifying Brush Holder Assembly To Armature
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Install the starter cover, and secure it to the brush holder assembly with the screws.

Fig 3: Identifying Starter Cover
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Assemble the shock absorber in the following procedures:
1. Apply grease to shock absorber (C), and assemble internal gear (B) to shock absorber bearing (A).
  NOTE: Align with the claw position of internal gear to assemble the shock absorber bearing.
  
  Grease: DENSO HL50
  
  Fig 4: Separating Shock Absorber Bearing From Internal
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2. Assemble the shaft to the internal gear.
  NOTE: Apply grease to the shaft sliding surfaces inside the internal gear.
  
  Grease: DENSO HL50
  
  Fig 5: Identifying Shaft
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3. Attach the snap ring to the shaft.
  NOTE: Use new snap rings.
  
  Fig 6: Attaching Snap Ring To Shaft
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Assemble the planetary gear to the internal gear.
1. Apply grease to the planetary gear installation position.
  Grease: DENSO HL50
2. Install the planetary gear to the pin.
3. Apply grease to the planetary gear, internal gear, and upper part of the pin.
  NOTE:
  - Apply grease so that it contact surfaces of each gear.
  - Be careful not to allow dirt to get in.
  Grease: DENSO HL50
  
  Fig 7: Identifying Planetary Gear
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4. Install the starter plate.
  
  Fig 8: Identifying Starter Plate
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Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.
  Grease: DENSO HL50
2. Install the overrunning clutch to shaft.
  
  Fig 9: Identifying Overrunning Clutch And Shaft
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3. Install stopper (B) to the shaft, then install snap ring (A).
  
  Fig 10: Identifying Snap Ring And Stopper
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4. Using a press, pressure fit stopper (B) into snap ring (A).
  
  Fig 11: Pressing Stopper Into Snap Ring
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Assemble the overrunning clutch, shock absorber, and shaft to the yoke as a single unit

Fig 12: Identifying Overrunning Clutch, Shock Absorber Bearing And Shaft
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Install the shift lever.
NOTE: Apply grease to the contact area of the shift lever.

Grease: DENSO HL50

Fig 13: Identifying Shift Lever
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Install the starter housing, and tighten through bolts on both sides.
Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)

Fig 14: Identifying Starter Housing
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Fig 15: Locating Starter Housing Bolts
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Install the starter seal.

Fig 16: Identifying Starter Seal
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Install the magnet switch assembly to the starter housing, and tighten the nuts.
NOTE: Apply grease to the shift lever installation position.

Grease: DENSO HL50

Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Fig 17: Locating Magnet Switch Assembly And Nuts
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Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.
Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

Fig 18: Identifying Magnet Switch Assembly
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