Starter 0.8 kW
Note: Use high temperature bearing and gear grease when assembling the starter.
1. Install the crown gear and carrier.
- A) Apply grease to the epicycle at the points of contact with the shock absorber and satellites.
- b) Align the groove on the epicycle with the tab inside the shock absorber.
- V) Insert and rotate the epicycle to secure the shock absorber.
- G) Apply high quality grease with additives to the bearing.
- d) Lubricate the washer and install it on the carrier.
- V) Install carrier and shock absorber.
- and) Install the washer and circlip using pliers.
2. Install the traction relay.
- A) Apply grease to the bushing and to the groove of the overrunning clutch stop bushing,
- b) Install the freewheel and stop sleeve to the carrier.
- V) Lubricate the retaining ring and install it in the carrier groove.
- G) Use a vise to crimp the circlip.
- d) While holding the freewheel, seat the carrier and install the stopper sleeve onto the retaining ring using a plastic-faced hammer.
3. Install the satellites.
- A) Apply grease to the satellites and carrier flange with guides.
- b) Install washer and 3 satellites.
- V) Install the plate, aligning its groove with the protrusion inside the shock absorber.
4. Install the drive arm and overrunning clutch with shock absorber.
- A) Apply a high quality grease with additives to the bearing in the drive side cover.
- b) Apply lubricant to the drive arm at the fulcrum.
- V) Install the drive lever to the freewheel.
- G) Align the tab on the shock absorber with the groove on the cover on the drive side.
5. Install new O-rings on the starter housing
6. Install the anchor in the starter housing.
7. Install the brush holder.
- V) Install the brush holder on the armature to the appropriate position.
- b) Using a screwdriver, depress the brush spring and connect the brush to the brush holder. Install 4 brushes in this way.
Note: check that the wires (+) brushes are not in contact with "weight".
8. Install manifold.
- A) Apply turbine oil with additives to the bearing in the cover on the manifold side.
- b) Install the cover using 2 new O-ring screws.
9. Install starter housing and anchor assembly.
- A) Align the groove in the starter housing with the bump on the shock absorber.
- b) Install the starter housing with anchor assembly and secure it with 2 bolts.
10. Install the traction relay.
- A) Install the cover on the traction relay.
- b) Install the traction relay and secure it with 2 nuts.
- e) Connect the wiring to starter terminal C and tighten the nut.
Starter 2.2 kW
Note: Use high temperature bearing and gear grease when reassembling the starter.
1. Install the drive lever on the freewheel.
2. Install the freewheel onto the shaft.
- A) Apply grease to freewheel and shaft.
- b) Install the freewheel and limiter sleeve onto the shaft.
- V) Install a new retaining ring on the shaft.
- G) Using pliers, press in the retaining ring.
- d) Make sure the retaining ring is installed correctly.
- e) Using a screwdriver, slide the stop sleeve over the circlip.
3. Install the shaft assembly and freewheel.
- A) Install the drive shaft and lever.
- b) Align the holes on the starter cover with the pins.
- V) Install the shaft and freewheel in the drive side cover.
- G) Install shock absorber.
4. Install the anchor plate.
- A) Install the anchor plate as shown in the illustration.
- b) Align the grooves on the epicycle and the tabs on the anchor plate.
- V) Install the anchor plate on the epicycle.
5. Install the brush holder on the anchor.
- A) Install 4 holders and four springs on the brush holder.
- b) Install 4 brushes on the brush holder.
- V) Install the brush holder on the anchor.
6. Install the drive side cover on the starter housing.
- A) Install the washer, drive side cover, and thrust washer with retainer.
- b) Check the gap between the retainer and the cover.
- A) Apply grease to the drive side cover.
- G) Install the drive side cover and secure it with two screws. Tightening torque: 1.7 Nm.
7. Install the starter housing on
- A) Align the shock absorber with the cutout on the body.
- b) Install the starter housing and anchor assembly with two bolts. Tightening torque: 8.5 Nm.
8. Install the traction relay.
- A) Install the core on the drive lever.
- 6) Install the return spring and drawbar with three screws. Tightening torque: 5.0 Nm.
- V) Connect the wiring harness to terminal C and secure it with a nut. Tightening torque: 8.0 mm.