Photo 17.1A Armature end cap (Bosch)
Photo 17.1B Starter armature clamp (Bosch)
Photo 17.1B Starter armature clamp (Bosch)
Photo 17.1D Removing the starter motor cover (Bosch)
2. Remove the brushes from the holder and then remove the holder from the armature shaft. Pull out the spacer washers installed between the brush plate and the armature block (see photo 17.2).
Photo 17.2 Removing the brush plate holder (Bosch)
3. Check the condition of the brushes: if they are so worn that their length is less than the minimum length specified in the Specifications, they should be replaced. New brushes that meet the latest standards are not equipped with shunt wires, so when installing this type of brushes, you first need to break off the old ones using a vice or hammer so that all the carbon is removed from the shunt wire, and then you need to completely strip the wires to prepare them for soldering. Insert the wire into the hole in the new brush and spread it there until it fills the entire hole. Hold the wire as close to the brush as possible with the pliers to ensure that the wire is in the correct position when soldering, and also to ensure that the soldering iron does not push the wire further than necessary, which will affect the flexibility of the wire. For this work you will need a soldering iron "pencil" power from 12 to 15 watts. After soldering the wire in place, remove any excess solder with a file, and check that the brush can move freely in its guide (see photo 17.3).
Photo 17.3 Commutator and brushes of the field coils of a Bosch starter motor
4. Wipe the starter motor armature and commutator clean with a piece of cloth soaked in gasoline.
5. Install the brushes into the holder, and then place the holder on the armature shaft, remembering to install two washers between the holder and the armature (see photo 17.5).
Photo 17.5 Bosch type starter brush holder plate
6. Install the back cover and secure it with two long bolts.
7. Install the armature shaft end cap after installing the rubber spacer ring, washer and shaft clamp.
Delco-Remy type
8. After removing the motor from the engine, placing it on a clean, level surface, unscrew and remove the two through-mount bolts from the rear cover. Also remove the two small screws that secure the brush holder.
9. Remove the rear cover, noting exactly how it is installed in relation to the wires coming from the solenoid. Reinstall the bearing bushing if it has come loose; it should usually remain in the lid.
10. Remove positive brushes (those connected to the field windings) from the holder, being careful not to damage the springs. Disconnect the brush holder from the motor.
11. Replace the brushes if they are so worn that their length is less than the minimum specified in the Specifications. Always replace all four brushes at the same time.
12. Replace negative brushes (those attached to the holder) by unsoldering the old ones and soldering new ones in their place. Hold the brush wires with pliers to prevent solder from getting on them and causing them to lose their flexibility.
13. Replace the positive brushes by cutting off the old ones at a suitable distance from the field windings. Solder the wires of the new brushes to the old ones, again making sure that the solder does not get on the wires and brushes.
14. Clean the switch with a non-fraying cloth soaked in gasoline. Make sure the brushes can move freely in their guides.
15. Insert the negative brushes into their holders, positioning the springs on the sides of the brushes so that the brushes are not yet fully lowered into place.
16. Prepare the brush holder for installation in the motor. Insert it into place and hold the positive brushes in a similar manner.
17. Carefully lift the spring of each brush so that it rests on the back of the brush; Now the brushes will take their normal position.
18. Install the bearing bushing and rear cover, making sure the screw holes on the cover and brush holder line up. Insert and tighten the brush holder mounting screws.
19. Install and tighten the motor through-mount bolts.
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