Something's gone Haywire (starter ?)

[bonanzadave]

I applied a little grease to the bearing and the shaft on the other end.

[bonanzadave]

There are some specific notches on the housing that need to line up with cutouts on the end cap and brush plate in order to reassemble. once you have that alignment put the two long screws back in.

[bonanzadave]

I tested it after that. 12vdc to the post and touch the starter case to the side stand.

[Grimly]

The only starter trouble I've had so far has been years of carbon dust being sticky with oily fumes and slowly sticking the brushes in place. Two like that, but the last one, even though it's got a fair bit of life left in it, really needs a new pair of brushes for the next 35 years.
Really must get around to ordering the repair kit, as I like to have a spare ready to go.

[bonanzadave]

Clean the starter well and then work the starter back from whence it came. Apply some grease to the oring to make sure it goes back in with the oring where it needs to be. Put the two bolts back in the mounting holes. Again mostly by feel.





Put the 10mm socket and short extension and swivel on a bolt. Then from above the carbs attach the long extension and tighten the bolts.

[bonanzadave]

Reinstall the starter cable and boot.

[bonanzadave]

If you took the stator/start clutch cover off and removed the gear set between the starter gear and starter clutch gear here is a good way to get it back on. Mine had a washer on both ends of the gear set on the shaft. Position the gear set in place and hold it snug. Remove the shaft and look in the hole to see where it needs to be to line up. Use a extension or something to get the inner washer lined up. Once it looks good slide the shaft in. Put the outer washer on the shaft.

[bonanzadave]

Now put the stator cover back on if you took it off and the starter cover. Almost done. Dont try this without these extensions, sockets, and swivel. Some other tools I used.

[Redman]

.....
Remove the starter cover. Best to have a 8mm socket,swivel,and a long 1/4 extension on your ratchet. Once the two 8mm bolts are out remove the cover.
..............

Ah, looks like the long extension and swivel joint made the most difficult portion of all this much easier.

Good pictures. Thanks.

Ah, you have the NipponDenso starter.
I have had the Matsuba (both, 850g and 1100g). For those is good to make marks to note the arrangement (clock) of the ends to the main part, as they can go back together such that will then not fit back in place in the engine.

.

[bonanzadave]

make marks to note the arrangement (clock) of the ends to the main part

Good idea Dave. Ill make note of that in the tutorial.

[Redman]

Take note or make physical marks on the endcaps and housing so when it comes time to reassemble you wont be scratching your head. ....,,,........

I think I recall this was a concern on the Mitsuba starter(s) that I have had, appears to not be much of a concern on your Denso starter that has the cable connection in the end bell that has the mounting bolts.

[bonanzadave]

It will not go together correctly if you dont line it up like what I show in post #17

[Brendan W]

It will not go together correctly if you dont line it up like what I show in post #17

There is a hole burned in my motor cover. Looks very like someone managed to get the motor back in with the terminal at 12 o'clock and then tried to fire up the bike

[Cipher]

nice instructive bit of starter porn

[bonanzadave]

nice instructive bit of starter porn

Hope it helps someone else in that predicament. Id like to see it in the GS bible (aka Basscliffs website) but I have no idea how to get a hold of the master.....