Hi-torque starter

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*With the starter on the bench, first use a paint marker to provide alignment marks on the main motor housing and the gear housing.  
 
*With the starter on the bench, first use a paint marker to provide alignment marks on the main motor housing and the gear housing.  
 
*Remove the three bolts holding the starter to the aluminum mounting block. For ease of re-installation, marking the clocking of the starter motor is suggested.
 
*Remove the three bolts holding the starter to the aluminum mounting block. For ease of re-installation, marking the clocking of the starter motor is suggested.
*Remove the two bolts holding the solenoid in place.
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e reverse order of the disassembly.  
*Remove the two long bolts from the starter motor, keeping the brush holder in place set it to the side.
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*Pay close attention to the orientation of the solenoid actuator as it must go back in the proper way.
*Remove the rubber insulation piece and the solenoid actuator making note of its orientation.
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*Using a small metal drift and small hammer (plastic or rubber) apply a few taps to the backside of the pinion gear - it should come out easily.
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*The pinion gear is held in place with a round clip that is held in place by a small metal casing. A couple of short taps with a metal drift should move the metal casing downward on the pinion shaft.
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*Remove the round clip and slide the old pinion gear out.
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*Apply a small amount of grease to the pinion shaft and slide it in place.
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*Replace the round clip and using a set of pliers, squeeze it tightly together.
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*The small metal casing should go back over the round clip, however I have found that it is not critical that it does as the round clip cannot dislodge once the pinion is placed back in the housing.
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*Place the pinion gear assembly back in the housing and using a plastic/rubber hammer, a few taps will seat it properly.
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*At this point the starter can be reassembled in the reverse order of the disassembly.  
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*Pay close attention to the orientation of the solenoid actuator as it must go back in the proper way.
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[[Category:Electrical]]
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[[Category:Engine]]
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Latest revision as of 22:23, 30 December 2024

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