ELECTRIC STARTER SERVICING
Starter Removal
IMPORTANT: Do not clean the starter drive while the starter motor and drive are installed on the powerhead. The cleaning agent could drain into the starter motor, washing dirt from the drive into the starter bearings and commutator.
Disconnect the battery cables at the battery.
Remove lower motor covers. Refer to Lower Cover Removal on p. 45.
Remove the starter positive (+) cable from post on starter.
Remove three starter mounting screws. Remove the starter.
- Screws
Starter Disassembly
Remove the retaining nut, spacers, spring and starter pinion from pinion shaft.
Mark the end cap and brush holder cap orientation. Remove the two thru-bolts.
Remove the end cap and thrust washer.
Remove brush holder cap from armature and frame assembly. Do not lose the brush springs.
Slowly, remove the armature from frame.
Starter Cleaning and Inspection
Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs.
Clean the commutator with 300 -grade emery cloth. If commutator surface is unevenly worn or pitted, turn it on a lathe. Remove any trace of oil or metal dust from commutator.
Check the armature on a growler for shorted turns using a test light or meter. Inspect armature insulation for indications of overheating or damaged windings. Clean off any carbon deposits or foreign matter which could contribute to failure of windings.
TYPICAL
Check permanent magnets and make sure they strongly attract any steel or iron object held inside frame. Weak magnetism could cause excessive RPM on No Load Current Draw Test on p. 97.
TYPICAL
After disassembling the drive, clean each part with Cleaning Solvent and inspect for wear and distortion.
If the pinion does not properly engage the flywheel, the pinion and screw shaft assembly could be worn, distorted, or dirty. Locate the cause of binding and correct it before completing the assembly.
Inspect and replace end cap thrust washer if distorted or worn excessively.
Starter Assembly
IMPORTANT: If removed, apply Locquic Primer and Screw Lock™ to the brush card screws before installing.
Place armature in frame.
Apply Moly Lube to the armature bushing.
Route the brush leads and install the springs and brushes.
IMPORTANT: Incorrect orientation of the brushes could damage the starter or cause reverse rotation.
- Brush card screws
- Armature bushing
Compress the brushes and springs with a modified putty knife.
Align and place brush holder cap firmly on armature and slide putty knife out, making sure the brushes are retained properly.
Install thrust washer. Align and place end cap onto armature shaft.
Apply Locquic Primer and Screw Lock to the threaded portion, and install the two thru-bolts. Tighten bolts to a torque of 100 to 110 in. lbs. (11 to 12.5 N·m).
Lubricate the splines (helix) of starter pinion shaft with Starter Bendix Lube. DO NOT use liquid or aerosol spray lubricants.
Install pinion, spacer and spring.
Install spacer and retaining nut. Tighten nut to a torque of 20 to 24 ft. lbs. (27 to 33 N·m).
Be sure spacer is not caught between shaft and retaining nut and that spacer is free to move.
To test the assembly and operation of the starter, refer to No Load Current Draw Test on p. 97.
Starter Installation
Apply Triple-Guard grease to the threads of the three starter screws and also to the washers.
Position the starter and install the screws and washers. Tighten screws to a torque of 168 to 192 in. lbs. (19 to 21 N·m).
Attach starter positive (+) cable to post with lock washer and nut; tighten securely.
Coat connections with Black Neoprene Dip.
CONNECTOR SERVICING
DEUTSCH Connectors
IMPORTANT: Electrical Grease is recommended. Incorrect grease application can cause electrical or warning system problems.
To disconnect the connector, press the latch and pull the connectors apart.
To connect the connector, confirm that the seal is in place. Clean off any old grease and dirt from connectors. Apply a light coat of Electrical Grease to seal only. Push connectors together until latched.
- Latch
- Seal
Terminal Removal
Use hook-end of Connector Service Tool, P/N 342667, to pull out wedge from receptacle, or use other end of tool to pry out wedge from plug. Use needle-nose pliers to remove wedge from 3-pin receptacle.
- Wedge
