Rebuilding the starter
Before removing your starter, drain the oil from
the bike. This is a good time to change the oil & filter if
needed so remember to pick up a filter.
--Disconnect the negitive battery bolt & cable
--Unbolt the positive lead from the starter, unbolt the starter from the case.
--Remove the 2 long bolts holding the
starter together. Disassemble the starter, noting how everything
fits together. Make a sketch or take polaroid pics to help you
remember where everything goes when you put it back together, if
--Also note the position of the thrust washers on the ends of
--Note the alignment marks on the center casing and end
plates for reassembly.
--Assuming you plan to replace the seal, grab
the metal lip with a pair of pliers and pull it out, or, place a flat
blade screwdriver under the lip and pry it out.
--Clean all oil soaked
parts well. I prefer to use spray type brake cleaner avalable at any
auto parts store.
--To do this job properly you should find a reputable
electric motor repair shop to turn the commutator, (the copper part the
brushes ride on), Undercut the mica, (the white substance between the
commutator strips) and balance the armature. they probably will be able to
hook you up with replacement brushes and springs if needed.
the spring clip and working from the "sealed" side of the bearing, gently
tap the bearing out of the casing with a long thin drift or punch and a
hammer. be sure to tap on the OUTSIDE of the bearing. This will take
a little patence, so take your time. If you use care, this bearing,
if not worn out, can be reused.
--Install the new bearing by placing a
socket SLIGHTLY smaller than the outer diameter of the bearing shell over
the bearing and tap into place.
--Install the spring clip and the new
seal in the same manner as the bearing.
--Before reassembling the
starter, I would recomend drilling a small 1/16 hole on the underside of
the starter casing on the seal end so that in the unlikely event that the
new seal should ever fail, any oil getting into the starter will tend to
drip out the hole. This serves two purposes: 1) this will act as an
indicator that there is a problem with the seal, and 2) hopefully allow
the oil a path out of the starter before it reaches the brushes on the
--Put the starter back together and install it on the bike,
change the filter and add fresh oil. Your hard work will be rewarded
with a starter that hopefully will be trouble free for the life of the