Engine Starting System & Charging System: Starter: Assembly

Apply grease to the sliding parts of the shaft.
Preparation items:

Grease: Multemp #6129 or equivalent

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Install the internal gear to the shaft.

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Install the overrunning clutch as follows:

Apply grease to the spline portion of the shaft.

Preparation items:

Grease: Multemp #6129 or equivalent

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Set the overrunning clutch.

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Pass a new stopper (B) through, and attach a new snap ring (A).

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Using a press, pressure fit stopper (B) into snap ring (A).

CAUTION: Do not apply any load to the internal gear.

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Install the overrunning clutch, internal gear, shaft and shift lever as a single unit to the starter housing.
NOTE: Apply grease to the moving parts of the shift lever.

Preparation items:

Grease: Multemp #6129 or equivalent

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Apply grease to the inside of the internal gear and pinion gear, and attach the pinion gear to the internal gear.
NOTE: Apply grease evenly to the contact surfaces of each gear.

Preparation items:

Grease: Molykote® AG650 or equivalent

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Install the plate (B) and seal rubber (A).

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Set the armature to the yoke.

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Attach the armature and yoke to the starter housing together as a single unit.
NOTE: As shown in the figure, match the protrusion of the yoke to the cut out of the starter housing.

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Use an appropriate tool (suitable attachment, etc.) to attach the brush holder.
NOTE: Be careful not to damage the brushes.

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Set the starter cover and install the bolts (A) and through bolts (B).
Tightening torque:
1. CVT model
  T1: 3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
  
  T2: 3.5 N.m (0.4 kgf-m, 2.6 ft-lb)
2. MT model
  T1: 3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
  
  T2: 6.1 N.m (0.6 kgf-m, 4.5 ft-lb)
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Install the magnet switch.
Tightening torque:
1. CVT model
  3.4 N.m (0.3 kgf-m, 2.5 ft-lb)
2. MT model
  5.9 N.m (0.6 kgf-m, 4.3 ft-lb)
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Connect the cable to the terminal M.
Tightening torque:
1. CVT model
  10.7 N.m (1.1 kgf-m, 7.9 ft-lb)
2. MT model
  10.7 N.m (1.1 kgf-m, 7.9 ft-lb)
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