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This has probably been documented before but, since I've done it today, I thought I would post here with some pix.
I wanted to paint the end cover of the starter motor. On the European bikes, this is black, like the rest of the engine so, since I had to remove the cover, I thought I'd do the entire motor whilst I was at it......
First, remove the two long cross headed bolts which secure the end cover. It is absolutely essential to use the correct size and profile of cross head screwdriver bit. Too small and it will damage the ends of the bolts. There is the usual bond between steel and alloy and they were very securely stuck. A correctly sized bit, with the starter motor in a vice so that downward pressure can be applied to the bit, makes things easy. I did not use a screw driver but used a ratchet drive from a small socket set..
The end cover at the gear end then comes off, revealing the planet gears and filthy old grease. There is also a paper type gasket which breaks of course....
The metal plate with bronze bush then pulls out of the starter body. There are shims behind it which only fit at the end of things..they can't be confused with the other end which is a different diameter... Note the filthy carbon brush assemblies in the starter body...
The bearing at the gear end can be checks for play by removing the circlip at the end of the splined shaft and taking off the cog..this enables you to grab the shaft and see if there is any play. In this instance, there was none...
At the other end, the alloy cover comes off easily to reveal a lot of black crud from the brushes.... Check that their is plenty of life le in the brushes themselves. Worn out brushes are very small.....
The armature, which pulls out of the starter body from the gear end, is dirty and dusty...
Clean the commutator with fine wet and dry ....
Gently remove any carbon or dirt from the commutator grooves. I used a snap knife blade...
Remove gears and clean out all the old grease...
Clean the brush end with a suitable solvent....carb cleaner or similar...
Apply fresh grease to the gears.... The blue ink is from using the casing to print onto gasket paper in order to make a new gasket...
This little tab is important....the inner plate with the bush also has a cut out and the body of the motor has a tab. They need to line up to get the gearbox end back on...
Use a solvent to clean all the muck out of the carbon brush cover end of things...
Lightly grease the end of the armature where it goes into the bronze bush.
The armature goes back into the starter body from the gear end and the carbon brushes need to be pulled back against their springs in order to get the commutator through...
The carbon brush end goes on last. Make sure the bolt holes both line up as it can fit n with them not aligned.....
Here's a pic of all the parts..
And the rebuilt motor.... Complete with freshly painted cover, using Prisone6's recommended enamel.....!
I wanted to paint the end cover of the starter motor. On the European bikes, this is black, like the rest of the engine so, since I had to remove the cover, I thought I'd do the entire motor whilst I was at it......
First, remove the two long cross headed bolts which secure the end cover. It is absolutely essential to use the correct size and profile of cross head screwdriver bit. Too small and it will damage the ends of the bolts. There is the usual bond between steel and alloy and they were very securely stuck. A correctly sized bit, with the starter motor in a vice so that downward pressure can be applied to the bit, makes things easy. I did not use a screw driver but used a ratchet drive from a small socket set..
The end cover at the gear end then comes off, revealing the planet gears and filthy old grease. There is also a paper type gasket which breaks of course....
The metal plate with bronze bush then pulls out of the starter body. There are shims behind it which only fit at the end of things..they can't be confused with the other end which is a different diameter... Note the filthy carbon brush assemblies in the starter body...
The bearing at the gear end can be checks for play by removing the circlip at the end of the splined shaft and taking off the cog..this enables you to grab the shaft and see if there is any play. In this instance, there was none...
At the other end, the alloy cover comes off easily to reveal a lot of black crud from the brushes.... Check that their is plenty of life le in the brushes themselves. Worn out brushes are very small.....
The armature, which pulls out of the starter body from the gear end, is dirty and dusty...
Clean the commutator with fine wet and dry ....
Gently remove any carbon or dirt from the commutator grooves. I used a snap knife blade...
Remove gears and clean out all the old grease...
Clean the brush end with a suitable solvent....carb cleaner or similar...
Apply fresh grease to the gears.... The blue ink is from using the casing to print onto gasket paper in order to make a new gasket...
This little tab is important....the inner plate with the bush also has a cut out and the body of the motor has a tab. They need to line up to get the gearbox end back on...
Use a solvent to clean all the muck out of the carbon brush cover end of things...
Lightly grease the end of the armature where it goes into the bronze bush.
The armature goes back into the starter body from the gear end and the carbon brushes need to be pulled back against their springs in order to get the commutator through...
The carbon brush end goes on last. Make sure the bolt holes both line up as it can fit n with them not aligned.....
Here's a pic of all the parts..
And the rebuilt motor.... Complete with freshly painted cover, using Prisone6's recommended enamel.....!
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