Starting System & Charging System (H4DO): Starter: Assembly

Apply grease to the shaft sliding surfaces of the internal gear assembly.
Grease:

Multemp #6129 or equivalent
Assemble the shaft to the internal gear assembly.

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Assemble the overrunning clutch as follows:

Apply grease to the spline portion of the shaft.
Grease:

Multemp #6129 or equivalent

Install the overrunning clutch to shaft.

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Pass stopper (B) through the shaft assembly, and attach snap ring (A).

NOTE: Use new stoppers and snap rings.

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Using a press, pressure fit stopper (B) into snap ring (A).

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Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.
NOTE: Apply grease to the moving parts of the shift lever.

Grease:

Multemp #6129 or equivalent

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Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.
NOTE:
- Apply grease evenly to the contact surfaces of each gear.
- Be careful that no debris becomes attached.
Grease:

Molykote® AG650 or equivalent

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Install seal rubber (A), plate (B), and seal rubber (C).

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Assemble the armature assembly to the yoke assembly.

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Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.
NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.

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Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.
NOTE: Be careful not to damage the brushes.

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Secure starter cover assembly to the brush holder assembly with screws (A).
Tightening torque:

1.4 N.m (0.1 kgf-m, 1.0 ft-lb)
Tighten through bolts (B) on both sides.
Tightening torque:

6 N.m (0.6 kgf-m, 4.4 ft-lb)

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Attach the magnet switch assembly to the starter housing assembly.
Tightening torque:

7.5 N.m (0.8 kgf-m, 5. ft-lb)

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Connect the cable to terminal M of the magnet switch assembly.
Tightening torque:

10 N.m (1.0 kgf-m, 7.4 ft-lb)

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