1. Remove the starter and place it on a clean bench. First, remove the armature end cap, which is attached with two small bolts (photo). Remove anchor bracket, gaskets and rubber o-ring (photo). Loosen and remove the two long bolts that hold the engine assembly together (photo). The end cap can now be removed to provide access to the brushes and mounting plate (photo).
2. Remove the brushes from the holder and the holder itself from the armature shaft. Remove spacers between brush plate and armature block where used.
3. Inspect the brushes; if worn below the minimum length given in the Specifications, they must be replaced. Cut off old brushes and solder new ones; clamp the wire on the brush with pliers to prevent the solder from spreading (photo).
4. Wipe the starter armature and commutator with a lint-free cloth soaked in gasoline.
5. Reassemble the brushes into the holder and install the holder onto the armature shaft, remembering to install two spacers between the holder and the armature where used.
6. Install end cap and with two long bolts.
7. Install the armature shaft end cap after installing the rubber o-ring, gasket, and shaft brace.
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