Disassembly and Reassembly

Starter / Exploded View / 1.4 kW:

Starter / Exploded View / 1.6 kW:

STARTER DISASSEMBLY

1. REMOVE STARTER STAY

Torque: 15.7 N.m (160 kgf cm, 12.5 ft.lbf)

2. 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)

1.0 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.

ASSEMBLY NOTE: Align the protrusion of the field frame with the groove of the magnetic switch.

d. Remove the O-ring.

ASSEMBLY HINT: Use a new O-ring.

3. REMOVE STARTER HOUSING FROM MAGNETIC SWITCH ASSEMBLY

a. Remove the 2 screws.

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

1.6 kW type
9.3 N.m (95 kgf.cm, 82 in.lbf)

b. Remove the starter housing with the pinion gear (1.6 kW), idler gear. bearing and clutch assembly.

ASSEMBLY HINT: Apply grease to the return spring and insert the return spring into the clutch shaft hole.

4. REMOVE CLUTCH ASSEMBLY AND GEARS FROM STARTER HOUSING

(3RZ-FE):

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

ASSEMBLY HINT: Apply grease to the steel ball insert the steel ball into the clutch shaft hole.

6. REMOVE BRUSH HOLDER

a. Remove the 2 screws. 0-rings and end cover from the field frame.

ASSEMBLY HINT: Use a new O-ring.

Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)

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

ASSEMBLY HINT: Use a new O-ring.

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.

ASSEMBLY NOTE: Check that the positive (+) lead wires are not grounded.

7. REMOVE ARMATURE FROM FIELD FRAME

ASSEMBLY HINT: Use high-temperature grease to lubricate the bearings and gears when assembling the starter.

STARTER ASSEMBLY
Assembly is in the reverse order of disassembly.