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 port side lower motor cover. Refer to Powerhead REMOVAL on p. 205.
Disconnect battery positive (+) cable from post on starter.
Remove the three screws from the starter.
002293
- Screws
Remove the starter from engine.
Disassembly
Remove the retaining ring, spacers, spring and starter pinion from pinion shaft.
002294
002295
Mark the end cap and brush holder cap orientation. Remove the two thru-bolts.
002296
Remove the end cap and thrust washer.
002298
Remove brush holder cap from armature and frame assembly. Do not lose the brush springs.
002299
Slowly, remove the armature from frame.
38288
Cleaning and Inspection
Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs.
002301
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 wind ings.
TYPICAL 24058 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. 137.
24057
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 fly wheel, 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.
Assembly
IMPORTANT: If removed, apply Locquic Primer and Screw Lock to the brush card screws before installing.
Place armature in frame.
Apply Extreme Pressure Grease 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.
002300
- Brush card screws
- Armature bushing
Compress the brushes and springs with a modified putty knife.
002309
Align and place brush holder cap firmly on armature and slide putty knife out, making sure the brushes are retained properly.
002310
Install thrust washer. Align and place end cap onto armature shaft.
002308
Apply Locquic Primer and Screw Lock to the threaded portion, and install the two thru-bolts. Torque bolts 100 to 110 in. lbs. (11 to 12.5 N•m).
002306
Lubricate the splines (helix) of starter pinion shaft with Starter Bendix Lube. DO NOT use liquid or aerosol spray lubricants.
002307 Install pinion, spacer and spring.
002305
Install spacer and retaining clip. Spacer must be raised to cover clip completely.
002311
002297
To test the assembly and operation of the starter, refer to No Load Current Draw Test on p. 137.
Installation
Apply Triple-Guard grease to the threads of the two starter screws, the double-ended stud, and also to the washers.
Position the starter and install the screws and washers. Torque to 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.
Attach the battery negative (–) cable to the starter frame. Attach the starter positive (+) cable to the starter’s positive terminal.
Coat all electrical connections with Black Neoprene Dip.
002292
- Black Neoprene Dip
