Mitsubishi S4S-D — Reassembly of Starter
Repair & overhaul
For the Mitsubishi S4S-D, from the Mitsubishi service manual.
Applies to: Mitsubishi S4S-D, Mitsubishi S4S engine
Before you start
- Ensure starter mounting face, brushes, commutator and current-carrying parts are not smeared with grease.
- On reassembly use a new stopper ring.
Procedure
- Apply grease to armature shaft gear, reduction gear, bearings, pinion shaft washer, stopper ring, pinion and lever sliding surfaces.
- Install a new stopper ring and pull pinion stopper until its groove engages.
- Adjust pinion shaft end play to 0.5 mm or less with adjusting washers.
- Install the lever in the correct orientation.
- Inspect pinion gap; add or reduce packings at magnetic switch to obtain 0.5 to 2.0 mm.
Tools required
- Puller Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Grease: MULTEMP PS2 (KYODO YUSHI) or equivalent
- Pinion shaft end play: 0.5 mm [0.02 in] or less
- Pinion gap: 0.5 to 2.0 mm [0.020 to 0.079 in]
Source: Mitsubishi service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.