5.3STARTER SOLENOID
SOLENOID ASSEMBLY
Disassembly
1. Remove field coil. See 5.2 STARTER, Field Coil Assembly.
2. Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.
3. Using a 9 mm socket, remove two hex screws with Phillips
recess to release solenoid housing from drive housing.
4. Use a rubber mallet to separate solenoid and drive hous-
ings, if necessary.
5. Remove return spring from solenoid plunger shaft.
Assembly
1. Install return spring on solenoid plunger shaft.
2. Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.
3. Lubricate armature bearing with LUBRIPLATE 110.
Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.
4. Install field coil. See 5.2 STARTER, Field Coil Assembly.
SOLENOID PLUNGER
Disassembly
1. Remove three hex screws to release solenoid cover.
2. Remove rubber gasket from solenoid cover flange.
3. Remove plunger and return spring.
Assembly
1. Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.
2. Install new rubber gasket on solenoid cover flange.
3. Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.
SOLENOID CONTACTS
Disassembly
1. Remove three hex screws to release solenoid cover.
2. Remove rubber gasket from solenoid cover flange.
3. Remove plunger and return spring.
4. Obtain Solenoid Contact Repair Kit.
5. Disassemble short post (field coil):
a. See Figure 5-10. Remove hex nut from post, if still
installed. Remove jam nut, wave washer, round
bushing and o-ring from post.
b. On inside of solenoid housing, remove post bolt, hold-
in terminal, contact plate and square bushing.
6. Disassemble long post (battery):
a. Remove hex nut from post, if still installed. Remove
jam nut, wave washer, round bushing and o-ring from
post.
b. On inside of solenoid housing, remove post bolt,
contact plate, square bushing and paper insulator
washer.
5-8 2008 Dyna Service: Starter
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