28.6 Ensure o-ring seats in its groove (arrowed)

4. Unscrew the two bolts securing the starter motor to the crankcase, noting the earth lead attached to the rear bolt (see illustration).

5. Slide the starter motor out from the crankcase and remove it from the machine (see illustration). Remove the O-ring on the end of the starter motor body and discard it as a new one must be used.

Installation

6. 

   28.8 Use two spanners when tightening the terminal nut

   Install a new O-ring on the end of the starter motor body and ensure it is seated in its groove (see illustration). Apply a smear of engine oil to the O-ring to aid installation.

7. Manoeuvre the motor into position and slide it into the crankcase. Ensure that the starter motor teeth mesh correctly with those of the starter idle gear. Install the mounting bolts, not forgetting to fit the earth lead with

the rear bolt, and tighten them securely (see illustration 28.4).

8. Connect the starter lead to the motor terminal and secure it with the nut. Hold the lower nut on the terminal with an open-ended spanner while tightening the top nut (see illustration). Make sure the rubber cover is correctly seated over the terminal.

9. Connect the battery negative (-ve) lead.

29 Starter motor - disassembly, ^ inspection and reassembly ^

Disassembly

1. Remove the starter motor (see Section 28).

2. Note the alignment marks between the main housing and the front and rear covers, or make your own if they aren't clear (see illustration).

3. Unscrew the two long bolts, noting how the D-shaped washers locate, and withdraw them from the starter motor (see illustration). Discard their O-rings as new ones must be used.

4. Wrap some insulating tape around the teeth on the end of the starter motor shaft - this will protect the oil seal from damage as the front cover is removed. Remove the front cover from the motor and remove the tabbed thrust washer from inside the front cover (see illustration).

29.2 Note the alignment marks (arrowed) between the housing and the covers

29.3 D-shaped washer (A) and O-ring (B)

29.4 Remove the front cover and the tabbed thrust washer (arrowed)

9»18 Electrical system

29.5 Insulating washer (A) and shims (B)

29.6 Remove the main housing and discard the O-rings

29.7a Separate the armature commutator (arrowed) from the brushplate ...

29.7b ... and remove the shims (arrowed) from the end of the shaft

29.8b ... and then the O-ring (arrowed)

29.8a Remove the terminal nut (A), washer (B) and insulating washers (C)...

29.9a Withdraw the brushplate assembly...

5. Remove the insulating washer and shims from the front end of the armature shaft, noting the order in which they are fitted (see illustration).

6. Remove the main housing and remove the cover O-rings from the housing and discard them as new ones must be fitted (see illustration).

7. Remove the rear cover and brushplate assembly from the armature commutator (see illustration). Remove the shims from the rear end of the armature shaft (see illustration).

8. Noting the order in which they are fitted, unscrew the terminal nut and remove it along with its washer, the insulating washers and O-ring (see illustrations).

9. Withdraw the terminal and brushplate assembly from the rear cover and remove the square insulating washer from the terminal (see illustrations).

10. Lift the brush springs and slide the brushes out from their holders, noting that one brush is attached to the terminal and the other is attached to the brushplate (see illustration).

Inspection

11 Check the general condition of all the starter motor components (see

29.9b ... and remove the square insulating washer (arrowed)

29.10 Brush (A) is attached to the terminal, brush (B) is attached to the brushplate

Electrical system 9*19

1. Long bolts

2. Front cover

3. Main housing

4. Rear cover

illustration). The parts that are most likely to require attention are the brushes. Measure the length of the brushes and compare the results to the brush length listed in this Chapter's

29.13 Continuity should exist between the commutator bars

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29.11a Starter motor components

5. O-rings

6. Tabbed washer

7. Insulating washer and front shims

8. Armature

9. Rear shims

10. Terminal bolt assembly

11. Brushplate assembly

Specifications (see illustration). If either of the brushes are worn beyond the service limit, renew the brush assembly. If the brushes are not worn excessively, cracked,