MARINE SERVICE

Starter Motors re-built Generic Method Statement

Materials and Tools:

• new brushes, bushings or bearings, and solenoid
• multimeter
• 600-1200 grit aluminum oxide sandpaper
• ratchet and socket set
• paint
• grease
• electrical contact cleaner
• wire brush
• scraper
• clean rags
• degreaser
• pliers
• adjustable wrench
• tape
• paint marker

Step 1:
Remove the starter motor from the engine.
*Note: Disconnect the battery prior to starter removal to avoid possibility of the short circuit.

Step 2:
Tape up any exposed holes on the starter and clean the outside using a scraper and wire
brush.
Use a paint marker to mark any case seams.
Remove the main power cable off the solenoid.
Remove the outer bolts (long and short) on the starter case.
*Note: Do not force the starter apart in order to avoid damage to plastic components.
Remove the solenoid.
Remove rubber cap holding the engagement lever.
Remove the final drive assembly.
Remove the two bolts on the backside and pull off the cap.
Remove the small rubber cap on the side that both holds and insulates
the cable
Pull back on the shaft to help the armature and brushes out.
Pop the metal clips back and remove the cap on the brush carrier.
Fully remove the metal clips and pull the brushes out.
Clean up any old lubricant on any parts with a clean rag.
Disassemble the final drive.
Remove the pinion gear and clutch assembly, inspect for any damage and replace if
necessary.
Inspect bushing inside the case for any damage and replace if necessary.

Bridge Plaza, 8-ci mərtəbə, Bakıxanov küç. 6, AZ1065, Bakı, Azərbaycan

Tel: +99412 555 08 61 dax. 100

Mob: +99450 225 91 19

office@marineservice.az
 MARINE SERVICE
Step 3:
Clean up any old dirt or lubricant.
Insert the new bushing with a hammer, make sure it sits into the same location as before.

Step 4:
Clean up the armature using electrical contact clean and brush.
Commutator resurface using 600 grit aluminum oxide sandpaper and a drill.
Clean up the commutator using electrical contact cleaner and ensure the spaces between
the commutator bars are clean.
Test the armature using a multimeter to determine if there are any faults.
Clean inside of the start case with contact cleaner to remove any contaminants.

Step 5:
Test the solenoid using a multimeter to determine if working correctly.
*Note: One will be measuring the resistance across the coil and another ensure the inner contacts are
functioning correctly once the solenoid has been activated.

Step 6:
Re-assembly:
Install the final drive back into the case (Make sure the armature turns freely).
Apply a light amount of oil to the bushings.
Install rubber cap, solenoid and then motor case.
Install the new bushes in the carrier and seat (should match the contour of the commutator).
Clean with electrical contact cleaner.
Assemble the case back together.
Reinstall on the engine.

Step 7: Testing
Test 1 - Checking the motor.
Connect the positive lead to the bottom terminal on the solenoid this should make the motor
spin, at high speed.
Test 2 - Checking the solenoid.
Connect the positive lead to the small terminal on the solenoid this should make the pinion
slide out and engage the ring gear.
Test 3 - Checking motor and solenoid.
Connect the positive lead to the top terminal on the solenoid. The starter motor should do
nothing it shouldn't spark or click. Connect another positive lead to the small
terminal on the solenoid the starter should fire up throwing the pinion out and spinning the
motor.

THIS DOCUMENT IS INTERNAL TO MARINE SERVICE LLC

Bridge Plaza, 8-ci mərtəbə, Bakıxanov küç. 6, AZ1065, Bakı, Azərbaycan

Tel: +99412 555 08 61 dax. 100

Mob: +99450 225 91 19

office@marineservice.az