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81 GS250T Starter rebuild

  • Thread starter Thread starter AdamJH
  • Start date Start date
A

AdamJH

Guest
My starter was acting funny and this post http://www.thegsresources.com/_forum/showthread.php?t=192239 made me jump into rebuilding my starter after everyone else telling me that it can't be done.
The original thread is for the larger bikes so I figured I'd post one up for the few 250 owners out there seeing as how everything seems to be slightly different on my bike :rolleyes:

Somehow this starter was still turning my engine over even though the magnets were completely free floating inside the case. Big difference here is that this starter only has two magnets, the bigger bikes have 4
https://sphotos-a.xx.fbcdn.net/hphotos-prn1/s720x720/523548_10151365773259746_1760953750_n.jpg
Magnet chips and dust galore.
https://sphotos-a.xx.fbcdn.net/hphotos-ash4/403989_10151365773369746_903467934_n.jpg
The cam chain tensioner must be removed to lift the starter out, just two bolts but a very tight squeeze even for a box end wrench. it can be done!
!Note! don't turn your engine without the tensioner installed!
https://sphotos-b.xx.fbcdn.net/hphotos-snc7/426714_10151365773734746_500614134_n.jpg
Everything all cleaned up. Make sure to sand all of the old epoxy off of the magnets and the case. flatten any burrs on the contacts. Check your brushes are longer than the 9mm service limit.
https://sphotos-a.xx.fbcdn.net/hphotos-ash4/431046_10151365773949746_2124248064_n.jpg
Use a good two part epoxy to re-stick the magnets to the case. I picked out the highest tensile strength possible for metal I could find at o-reilly's auto parts. Which happened to be almost 4,000psi steel strengthened J-B Weld, it's also good up to 550 degrees:D
https://sphotos-b.xx.fbcdn.net/hphotos-ash4/394458_10151365774084746_2067887829_n.jpg
Use a lint roller sheet to get the rest of the magnet dust off your parts before you attach them! I'm a genious:clap:
https://sphotos-b.xx.fbcdn.net/hphotos-snc7/488200_10151365774164746_1613722599_n.jpg
Lastly, make sure your magnets line up like so. Otherwise your bolt holes wont line up properly. I found that the brush plate cover will actually fit in two positions which confused the heck outta me when I was fit testing the magnets. There are two notches in the cover, one is for the notch in the case and the other is a drain hole
https://sphotos-a.xx.fbcdn.net/hphotos-ash4/320125_10151365774314746_31834235_n.jpg
That's about it for now, just waiting for my epoxy to set up around 10AM tomorrow. Details will follow!
 
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