8.25
Section 8
Electrical System and Components
8
Figure 8-53. Brush Installation Tool with Extension.
d. Hold the starter assembly vertically on the end
housing, and carefully place the tool (with
extension) and assembled original brush holder
assembly onto the end of the armature shaft.
Slide the brush holder assembly down into place
around the commutator, install the positive (+)
brush lead grommet in the cutout of the frame.
See Figure 8-54.
Figure 8-54. Installation Using Tool with Extension.
11. Install the end cap onto armature and frame,
aligning the thin raised rib in the end cap with
the corresponding slot in the grommet of the
positive (+) brush lead.
12. Install the two thru bolts, and the two brush
holder mounting screws. Torque the thru bolts to
5.6-9.0 N·m (49-79 in. lb.). Torque the brush
holder mounting screws to 2.5-3.3 N·m
(22-29 in. lb.). See Figures 8-55 and 8-56.
Figure 8-55. Torquing Thru Bolts.
Figure 8-56. Torquing Brush Holder Screws.
13. Hook the plunger behind the upper end of the
drive lever, and install the spring into the
solenoid. Insert the three mounting screws
through the holes in the drive end cap. Use these
to hold the solenoid gasket in position, then
mount the solenoid. Torque the screws to
4.0-6.0 N·m (35-53 in. lb.).
14. Connect the positive (+) brush lead/bracket to the
solenoid and secure with the hex nut. Tighten/
torque the nut to 6-9 N·m (53-79 in. lb.), do not
overtighten. See Figure 8-57.
Figure 8-57. Positive (+) Brush Lead Connection.
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