Removal and Installation
REMOVAL1. REMOVE V-BANK COVER
2. DISCONNECT ACCELERATOR CABLE
3. REMOVE INTAKE AIR CONNECTOR
4. REMOVE INTAKE MANIFOLD ASSEMBLY
5. REMOVE STARTER
a. Remove the 2 bolts holding the starter to the cylinder block.
b. Disconnect the starter from the cylinder block.
c. Disconnect the starter connector.
d. Remove the nut, bolt and disconnect the starter wire.
e. Remove the bolt, and disconnect the engine wire protector from the starter.
f. Remove the starter.
REPLACEMENT
1. REPLACE REAR BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
2. REPLACE FRONT BEARING
a. Using SST, remove the bearing.
SST 09286-46011
b. Using SST and a press, press in a new bearing.
NOTE: Be careful of the bearing installation direction.
SST 09286-00030
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove magnetic switch end cover. Remove the 3 bolts, end cover, gasket and plunger.
b. Inspect contact plate for wear.
Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove terminal kit parts.
1. Using SST, loosen the terminal nuts.
SST 09810-38140
2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper.
d. Temporarily install these new terminal 30 kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
e. Temporarily install these new terminal C kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Terminal insulator (outside)
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
f. Temporarily tighten the terminal nuts.
Gauge Pressure:
g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force: 981 N (100 kg, 221 lb)
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied. Gauge pressure:
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 Nm (170 kg.cm, 13 ft.lb)
NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean contact surfaces of contact plate and plunger.
Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp with the 3 bolts.
Torque: 3.6 Nm (37 kg.cm, 32 in.lb)
INSTALLATION
1. INSTALL STARTER
a. Install the engine wire protector to the starter with the bolt.
Torque: 9.81 Nm (100 kg.cm, 84 in.lb)
b. Connect the starter wire with the nut.
Torque: 9.81 Nm (100 kg.cm, 84 in.lb)
c. Connect the starter connector.
d. Connect the starter to the cylinder block.
e. Connect the engine wire with the bolt.
f. Install the starter with the 2 bolts.
Torque: 39 Nm (400 kg.cm, 29 ft.lb)
2. INSTALL INTAKE MANIFOLD ASSEMBLY
3. INSTALL INTAKE AIR CONNECTOR
4. CONNECT ACCELERATOR CABLE
5. INSTALL V-BANK COVER