Starting/Charging (H4SO): Assembly: Notes

NOTE: Apply grease to the following parts before assembly.

• Sleeve bearing
• Pinion shaft rotational portion
• Shaft spline portion
• Inside of reduction system
• Lever fulcrum/Clutch rotational portion

1. Install the overrunning clutch to the shaft assembly.
2. Use the following procedures to install stopper to the shaft assembly.
   1. Use the appropriate tool (such as the right size of socket wrench) to lightly tap on the ring to insert it into the shaft groove.
      Fig 1: Installing Stopper To Shaft Assembly

      
   2. Using the ST, press the stopper into the ring.
   Fig 2: Pressing Stopper Into Ring Using ST

   
3. Be careful of the following to install the shaft assembly to the front bracket.
   1. Lever direction
      Fig 3: Installing Shaft Assembly To Front Bracket

      
   2. Internal gear position
   Fig 4: Identifying Internal Gear Position

   
4. Install the plate.
   Fig 5: Identifying Plate

   
5. Install the planetary gear.
6. Be careful of the installation position to install the packing A and B.
   Fig 6: Identifying Installation Position Of Packing A And B

   
7. Install the armature to the yoke assembly.
8. Align the yoke assembly with the groove and install it to the front bracket.
   Fig 7: Aligning Yoke Assembly With Groove

   
9. Use the following procedures to install the brush holder to the yoke assembly.
   1. Push the brush into the brush holder, then use the appropriate tool (such as the right size of socket wrench) to fasten in position.
      Fig 8: Identifying Brush Into Brush Holder

      
   2. Align the brush holder with the groove in the yoke assembly, the slide to install.
   Fig 9: Identifying Brush Holder With Groove In Yoke Assembly

   
10. Align the rear cover groove with the brush holder assembly to install.
    Fig 10: Identifying Rear Cover Groove And Brush Holder Assembly

    
11. Install the rear cover set.
    Fig 11: Identifying Rear Cover Set

    
12. Use the following procedures to install the switch assembly to the front bracket.
    1. Insert the plunger and plunger spring into the switch assembly.
    2. Hook the protrusion on the plunger onto the lever end, then install to the front bracket.
    Fig 12: Identifying Switch Assembly

    
13. Install the connector to the switch assembly terminal M.

Fig 13: Identifying Switch Assembly Terminal M