Disassembly and Reassembly

Starter Motor Exploded View:

STARTER DISASSEMBLY

ASSEMBLY HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter.

1. REMOVE FIELD FRAME AND ARMATURE







a. Remove the nut, and disconnect the lead wire from the magnetic switch terminal.

Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf)







b. Remove the 2 through bolts.

Torque:
1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)







c. Pull out the field frame with the armature from the magnetic switch assembly.
d. Remove the O-ring.

ASSEMBLY HINT: Use a new O-ring.


ASSEMBLY HINT: Align the protrusion of the field frame with cutout of the magnetic switch.

2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR







a. Remove the 2 screws.

Torque:
1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf)
2.0 kW type: 9.3 N.m (95 kgf.cm, 82 in.lbf)







b. Remove these parts from the magnetic switch assembly:
1. Starter housing
2. Return spring
3. Bearing
4. Idler Gear
5. Starter Clutch assembly

(3RZ-FE):

3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch shaft hole.

4. REMOVE BRUSH HOLDER







a. Remove the 2 screws and 2 O-rings, and pull the end frame from the field frame.

Torque:
1.4 kW type: 1.5 N.m (15 kgf.cm, 13 in.lbf)
2.0 kW type: 3.8 N.m (39 kgf.cm, 34 in.lbf)

ASSEMBLY HINT: Use a new O-ring.

b. Remove the O-ring from the field frame.

ASSEMBLY HINT: Use a new O-ring.

(3RZ-FE):

c. Using a screwdriver hold the spring back and disconnect the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.

5. REMOVE ARMATURE FROM FIELD FRAME



STARTER ASSEMBLY
Assembly is in the reverse order of disassembly.