How to? Change starter brushes.

[Ed74mnd]

Hello,

After receiving the starter brushes for my 2 brush Nippondenso starter (GSX1100) i am having difficulty fitting them.
1 brush attaches to the positive feed bolt. how? OEM fitup seems to fuse this to metal?

the other brush lead is held by folding a metal tab over the top.

is there some kind of special method to attach the brush lead to the metal tang on the bolt??

Cheers

Ed

[jimcor]

I soldered mine on. Called the local starter/alternator rebuild shop and asked him what kind of solder he used, he ended up giving me a couple of feet for free. You must be careful not to completely saturate the braid with solder or it won't flex as your brush wears, and you will have ruined the new part.

I couldn't get that darn metal tab on the plate to open up. Ended up cutting the old braid and soldering the new to it. Again be careful you don't saturate the new braided lead with solder.

[Ed74mnd]

Thanks Jim.

will try that,

I had soldered it to a bit of the old braid, I soon leanrt why the lead was insulated..

the increased height of the braid touched on to the alternate brush retaining spring and promptly heated up (luckily sort of..) and the solder let go and thus avoided a major meltdown. the brush spring lost it's springiness as a result too .. hmm

I will try get some solder (i am using normal elctronic silver solder) as I cant get the solder to stick to the brush plate or tang.

Cheers

Ed

[jimcor]

That's all I had too was Radio-TV/electronics solder. I was worried about the melting temp which is why I called the starter shop. Don't really know what composition or melting point the stuff they gave me is, the owner left the stuff with the hired help. Nice guys tho'!

[Macmatic]

I soldered mine on. Called the local starter/alternator rebuild shop and asked him what kind of solder he used, he ended up giving me a couple of feet for free. You must be careful not to completely saturate the braid with solder or it won't flex as your brush wears, and you will have ruined the new part.

I couldn't get that darn metal tab on the plate to open up. Ended up cutting the old braid and soldering the new to it. Again be careful you don't saturate the new braided lead with solder.

You can squeeze the braid with small needle nose pliers or hemostats to keep the solder from wicking up it. Use a rubber band or something on the pliers to free up a hand. It has to be fairly tight.


Don't let this make you go TOO heavy on the solder, I've had pliers stick to the braind a little...

/\/\ac

[Planecrazy]

I guess I got lucky ... when I ordered the replacement brushes for my starter they were already attached to their respective housings (which of course were part of the replacement price). I spent around $45 for both parts of the brush assembly, which included new springs, bolt, etc...

Steve 8)

[volks28]

Just curious, could I use a MIG to spot weld it on?

[jimcor]

I guess I got lucky ... when I ordered the replacement brushes for my starter they were already attached to their respective housings (which of course were part of the replacement price). I spent around $45 for both parts of the brush assembly, which included new springs, bolt, etc...

Steve 8)

I went the cheapie route. Two brushes and two springs $13.95.

Hmm, now I remember, your starter is the 4 brush model. Lots more to fool with, not a bad price at all.

[Ed74mnd]

thanks for the tips guys.

I ended up removing most of the old braid with a sharp knife.. I thne soldered the new braid to this and it works a charm.

NEXT PROBLEM....

The starter works and the starter gear rotates clockwise (is this the correct direction?)

however the flywheel does not engage.

so my hunch is the starter clutch has packed it in.

question is.... it was working 5 weeks ago, why would it suddenly give up?

and which way does the flywheel rotate.. clockwise or anti clockwise?

Cheers

Ed

[jimcor]

Ed, also read your post to the 850 rider. Is there any chance when reinstalling the brush plate that you misaligned it?. I'm grasping at straws and guessing here. If indeed it did reverse spin direction that could be the only thing I could think of. And I really might be off track... I am clueless about direction of spin. even tho my repair is just a couple of weeks old that is something I just took for granted and never checked.

[Ed74mnd]

Hi Jim,

it is a strange one,

I know the brush plate can be 180? out, purely because the long screws must pass thru to hold the starter end caps together.

My gut feel is that the starter clutch is fine, my other feeling is the brsuh plate is 180? out.

I didnt mark the alignment of the brush plate unfortunately being my first re-build I was grappling with the starter and its contents sprang out unexpectedly.

Thanks for your comments, they do help me alot.

and great forum too.. every time I think my bike is getting to me, I cruise in here and all the positive remarks help me cope and fix the bike.

bike therapy lol


cheers

Ed

[jimcor]

I was grappling with the starter and its contents sprang out unexpectedly.
cheers

Ed

Several guys warned me about this, so I was very careful to make sure I promptly went and had a scattering of starter parts. Don't feel bad. Welcome to the club.

[Ed74mnd]

the starter did indeed end up spinning the opposite direction.

havent yet turned the brushes about.

A cheap Mitsuba starter fell into my hands and worked straight up.

thx for your help

Cheers

Ed