M20C-FKS, M20D-FKS STARTING  STARTER(for 1.2 kW Type)  REASSEMBLY  

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High-temperature Grease

Apply high-temperature grease to the pinion drive lever as shown in the illustration.

HINT:

Apply approximately 0.1 g (0.004 oz) of high-temperature grease to each section.

1.229,0.844 1.979,0.594 1.979,0.594 2.146,0.594 true 1.646,1.979 1.906,1.979 1.906,1.979 2.177,1.313 true 2.208,0.5 2.521,0.656 0.313,0.156 10 false *a 1.438,1.896 1.75,2.052 0.313,0.156 10 false *b

*a	Cutout
*b	Protrusion

Align the cutout of the starter drive housing assembly with the protrusion of the starter center bearing clutch sub-assembly and install the starter center bearing clutch sub-assembly.

1.958,0.958 2.313,0.635 2.313,0.635 2.531,0.635 false 2.802,1.927 3.094,1.927 false 3.125,1.833 3.333,2.052 0.208,0.219 10 false *1 2.542,0.552 2.854,0.708 0.313,0.156 10 false *2

*1	Washer
*2	Starter Center Bearing Clutch Sub-assembly

Install the washer to the starter center bearing clutch sub-assembly as shown in the illustration.

Install the rubber seal to the starter drive housing assembly.

Install the starter commutator end frame assembly to the starter brush holder assembly as shown in the illustration.

HINT:

If the parts are not aligned correctly, the through bolt cannot be attached.

Spread the brushes on the starter brush holder assembly, and install the starter armature assembly to the starter brush holder assembly.

1.031,0.635 1.344,0.635 1.344,0.635 1.646,1.052 false 1.01,1.344 1.406,1.344 false 1.063,1.854 1.458,1.854 false 0.854,0.552 1.167,0.75 0.313,0.198 10 false *3 0.844,1.24 1.156,1.438 0.313,0.198 10 false *1 0.917,1.76 1.229,1.958 0.313,0.198 10 false *2

*1	Starter Yoke Assembly
*2	Starter Brush Holder Assembly
*3	Starter Armature Assembly

Install the starter yoke assembly while holding down the starter armature assembly and starter brush holder assembly with the handle of a hammer.

HINT:

The starter armature assembly will be attracted by the magnetic field of the starter yoke assembly. Hold the starter armature assembly with the handle of the hammer.

0.958,0.76 1.188,0.208 1.188,0.208 1.417,0.208 false 1.417,0.771 1.927,1.604 1.927,1.604 2.229,1.604 true 1.417,0.104 1.729,0.26 0.313,0.156 10 false *a 2.281,1.521 2.594,1.677 0.313,0.156 10 false *b

*a	Protrusion
*b	Cutout

Align the cutout of the starter yoke assembly with the protrusion of the starter center bearing clutch sub-assembly.

Using a 7 mm deep socket wrench, install the starter yoke assembly with the 3 through bolts.

Torque:

3.2 N*m (33 kgf*cm, 28 in.*lbf)

0.656,1.083 0.813,1.083 0.813,1.083 0.958,0.938 false 0.667,0.396 0.854,0.396 false 0.896,0.333 1.208,0.531 0.313,0.198 10 false *1 0.5,0.969 0.813,1.167 0.313,0.198 10 false *a

*1	Pinion Drive Lever
*a	Hook
	High-temperature Grease

Apply high-temperature grease to the magnet starter switch assembly as shown in the illustration.

Install the magnet starter switch assembly with the 2 bolts.

Torque:

3.5 N*m (36 kgf*cm, 31 in.*lbf)

Connect the lead wire to terminal M with the nut.

Torque:

9.0 N*m (92 kgf*cm, 80 in.*lbf)

0.354,0.958 0.688,0.958 false 0.344,0.729 0.583,0.729 false 0.198,0.875 0.51,1.031 0.313,0.156 10 false *1 0.156,0.635 0.469,0.792 0.313,0.156 10 false *a

*1	Wire Harness
*a	Nut

Install the wire harness with the 2 nuts.

Torque:

6.5 N*m (66 kgf*cm, 58 in.*lbf)