| |
Starter
Re-Build Tech Tips
The following Starter Rebuild tech tips
are applicable to most ATVs |
 |
Two types of brushes will cover most to the ATV starter
motors out there. 2 brush or 4 brush for Denso starter motors and
2 brush or 4 brush for Mitsuba starter motors. Be sure to know who
manufactured the starter you are working on (Denso or Mitsuba). This
information, along with the starter ID#, can usally be found on the
starter motor end cap. |
| Start by removing the bolts holding on the starter motor
reduction gear cover. Witht he cover removed, the upper and lower
set of reduction gears can be removed (if applicable). Remove the
nut from the terminal stud. Then loosen and remove the bolts holding
the starter motor to the crankcase. Wiggle the starter motor to break
the seal tension and remove the motor from the case. |
 |
 |
Now, remove the long starter motor case bolts and you're
ready to remove the brush cap from the case. If the brushes are worn
out, the case will be full of powdered brush material. With the shortening
of the brushes, the spring tension holding them against the communtator
will decrease to a point causing electrical arching. |
| Next, remove the positive (+) brush and
terminal from the starter brush cap. Make sure you keep the order
of the washers straight, this will be important during re-installation.
When removing brushes from the brush holder, use needle nose pliers
to help position the flat spring allowing removal of the brush. If
the spring slips off, it usually requires some force to replace. |
 |
 |
Before installing new brushes, make sure all of the
copper contacts of the commentator are clean. The easiest way to do
this is gently abrade away the burnt coating with a thin strip of
emory cloth and a little WD-40 for lubrication. Make sure you remove
material evenly from top to bottom and remove no more material than
necessary. |
| Now you're ready to install new N2® replacement
brushes for your particular application. Measure the lead length of
the factory leads on the brushes and cut your replacement brushes
to the same length. Flux them and "tin" with solder. |
 |
 |
Next, solder the tinned lead to the brush plate. The
negative (-) is usually attached to the brush holder plate and the
positive (+) to the terminal stud. The positive (+) lead needs to
have a piece of woven insulating sleeve placed over the lead prior
to soldering it on the positive (+) terminal stud. |
| Place the brushes in the slots so that the curve of
the brush corresponds to the curve of the armature, and then slide
the spring back into position. Slide the positive (+) terminal stud
carefully into the brush cap then replace ALL the fiber washers previously
removed in the exact reverse order of removal. Now, slide the brushes
up into their slots and insert the armature. |
 |
 |
With the armature installed you are ready to install
the rest of the starter case. Align the indicator marks when assembling
the center case and end cap. Insert the long case screws and tighten
evenly until the rubber sealing O-ring is snug. With the starter motor
assembled, it should be tested before reinstalling it in the motor
cases. Use a charged battery and jumper cables. Attach the negative
(-) to the starter mounting ear and the positive (+) is just touched
to the positive (+) terminal stud. If everything was assembled correctly,
the starter motor should torgue strongly in your hand and spin radidly. |
| |
|
|
