Note: Use high temperature grease to lubricate the bearings and gears when assembling the starter.
1. Lubricate the bearings and insert the armature into the starter housing.
2. Install the brush holder.
- A) (Starter 2.2 kW) Align the protrusion of the brush holder with the groove in the starter housing.
- b) Install the brush holder into the starter housing.
Starter 2.2 kW
- V) Using a screwdriver, bend the brush spring back and install the brush into the brush holder.
Note: check that the wires (+) brushes are not in contact with "weight".
- V) (Except starter 2.2 kW) Install a new O-ring into the groove in the starter housing.
- G) (Except starter 2.2 kW) Install a new O-ring on the screw.
- d) (Except starter 2.2 kW) Install the starter cover on the manifold side and secure it with two screws.
3. Lubricate the steel ball and insert the ball into the freewheel shaft bore.
4. Install the freewheel and drive side starter cover.
- A) Lubricate the return spring, freewheel, idler gear and bearing.
- b) Insert the spring into the hole in the traction relay assembly.
- V) Install the following parts:
- (Starter 1.0 kW)
- (1) overrunning clutch assembly,
- (2) intermediate gear,
- (3) bearing.
- (Starter 1.2 kW)
- (1) intermediate gear.
- (2) bearing.
- (Starter 1.4 kW)
- (1) intermediate gear,
- (2) bearing,
- (3) drive gear.
- (Starter 2.2 kW)
- (1) overrunning clutch assembly.
- (2) intermediate gear,
- (3) bearing.
- (4) drive gear.
- G) Connect the starter cover on the drive side to the traction relay, securing it with two screws.
5. Install the starter housing and anchor assembly.
- A) Install a new O-ring into the groove in the starter housing.
- b) (Except starter 2.2 kW) Align the protrusion on the starter housing with the groove on the traction relay.
Except starter 2.2 kW
- V) (Starter 2.2 kW) Align the embossed mark (benchmark) on the starter housing with a label on the traction relay housing.
Starter 2.2 kW
- G) Install the starter housing and anchor assembly with the 2 tie bolts.
- d) Connect wire to terminal "WITH" and secure it with a nut.
6. Install the wire lead. Install the wire lead and secure it with the bolt, spring washer and screw.
7. (3S-FE, 4S-FE) Install the duster.