3to 11hp 4-cycle l-head engines - Small Engine Suppliers
3to 11hp 4-cycle l-head engines - Small Engine Suppliers
3to 11hp 4-cycle l-head engines - Small Engine Suppliers
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INSPECTION AND REPAIR<br />
1. The pinion gear parts should be checked for damage<br />
or wear. If the gear does not engage or slips, it should<br />
be washed in solvent ( rubber parts cleaned in soap<br />
and water) to remove dirt and grease, and dried<br />
before reassembly. Also check the armature and drive<br />
nut splines for wear or damage. Replace parts as<br />
necessary.<br />
2. The brushes and brush card holder should be<br />
checked for wear. With the armature in place and the<br />
brushes engaging the commutator surface, check the<br />
brushes for wear. Brushes should be replaced if the<br />
brush wire approaches the bottom of the brush holder<br />
slot. Brush springs must exhibit enough strength to<br />
keep tension on the brushes and hold them on the<br />
commutator.<br />
3. The field windings can be checked using a continuity<br />
light or ohmmeter. Attach one lead to each field coil<br />
connection. Continuity should exist between each<br />
field coil connection, and no continuity should exist<br />
between the field coil connections and the starter<br />
housing (diag. 36 & 37).<br />
4. The armature should be checked for glazing or wear.<br />
If necessary the armature can be turned down in a<br />
lathe. While rotating, polish the commutator bars<br />
using a piece of 00 sandpaper (diag. 38). Light<br />
pressure and back and forth movement should be<br />
used. Recut the commutator bars to a depth equal to<br />
the width of the insulators between the bars. Check<br />
for continuity between the copper commutator bars<br />
and the iron of the armature, none should exist (diag.<br />
39). If any is noted the armature must be replaced.<br />
FIELD COIL<br />
CONNECTORS<br />
BRUSH<br />
SPRINGS<br />
FIELD COIL<br />
CONNECTORS<br />
CONNECTION POINT OF<br />
POWER CORD LEADS<br />
12 VOLT 36 120 VOLT<br />
37<br />
38 39<br />
Brush Card Replacement<br />
1. Loosen but do not remove the two nuts on the starter terminal post.<br />
2. Remove the nuts holding the end cap in place. Remove the end cap and the thrust washer.<br />
3. Grasp the thru bolts using a vise grip positioned as close to the flanged end as possible to prevent thread<br />
damage. Remove the two nuts holding the driving end cap in place. Remove the armature and driving cap assembly,<br />
followed by the two thru bolts. Notice the position of the brush ground eyelet under the thru bolt flange.<br />
4. Note or mark the position of the connectors of the brush wires. Use a wire cutter to clip the solid field wires as<br />
close to the connectors as possible.<br />
5. Note or mark the brush card in the starter housing and remove the brush card assembly. Clean the accumulated<br />
dirt off all starter parts. Scrape the insulating varnish off the last 1/2" (12.7 mm) of the solid field wires.<br />
6. Insert the new brush card into position while guiding the solid field wires through the proper slots in the brush<br />
card.<br />
7. Crimp and solder the brush leads to the solid field wires. Use a needle nose pliers or vise grip to hold the woven<br />
brush lead close to the connector while soldering. This prevents solder and heat from flowing up the brush lead.<br />
Insulate the crimped connection nearest the starter terminal post using electrical tape or heat shrink tubing.<br />
Route the wires to prevent damage during assembly.<br />
8. Install the armature into the housing while spreading the brushes. Install the thru bolts while checking to make<br />
sure the bolts go thru the ground brush eyelet terminals. Install and tighten the drive end thru bolt nuts, but do not<br />
overtighten.<br />
9. Install the thrust washer (cupped side faces towards the end cap) on the end of the armature and then install the<br />
starter end cap. Secure the cap with the locking nuts and tighten the nut on the starter terminal post. Rotate the<br />
armature by hand to check for binding before installation on the engine.<br />
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