1.3L Starter rebuild

[Genchaos]

Part 1

First off this rebuild is for a stock starter from a Samurai 1.3L engine. I?ve taken apart and put these back together many, many times in one day. So for those having troubles here?s how to take it apart and put it back together. This is a starter I have kept to do this article and does not work due to the gear.

Tools required: 8mm socket with socket wrench
          Screwdriver

1. Remove the wire from the negative terminal ( put the bolt back on the negative terminal to aid in putting it back together) and remove the 2 screws holding the solinoid to the drive housing. (rubber and metal plate are missing from the pic)

There will be a plunger and a spring inside with 2 screws, a rubber piece and a metal piece.

2. Remove 2 small screws and the 4 large hex head bolts.

3.Crack the starter like an egg. A few light taps with a hammer or something equivelant will do it.

The cap will come off and then the drive housing.

4. Remove the armature from the housing and the Plastic lever

Congratulations you have disasembled a starter

Steve

 

[Genchaos]

Part 2

Check the brushes

Grease these areas

And using sandpaper or something eqvilant to clean and rust or dirt of any areas that need it

Steve

 

[Genchaos]

Part 3 Putting it back together

1. Install armature into drive housing with the plastic lever(wide side) attached around the gear

2. Install solinoid plunger onto the small opening of the plastic lever

3. Install sping into solinoid and then install over the plunger ensuring the tab for the ignition wire is down when the starter is installed to the vehicle. The negative terminal should be one closest to the housing (the one with the nut on it from disassembly)

4. Install the armature housing over the armature, making sure that the brushes are pushed in so they will slide onto the armature. Make sure that the wire is towards the solinoid and attach the wire to negative terminal. (the one with the nut on it from the disassembly)

5. Install cap so that the opening slides over the wire and the rubber. Install the 2 long bolts and use the hole in the drive housing to line up the bolt to the hole.

6.Then install the 2 small screws.

7. Do a "bench test" on the zuk by hooking up the negative and positive cables to the starter as well as the ignition wire. Rest the starter on something so it won't move and have someone turn the ignition. The starter should operate properly. Now install it to the samurai, cross your fingers and turn the key.

Congratulations you have a rebuilt starter.

If there are any suggestions or corrections let me know and I will change it

Steve

 

[nc_zuk]

Did some guy named Moto take your pics?

 

[Biggerhammer]

It looks like some of those pics were profesionally blurred to protect the identity of the Snowman...  [smiley=biggrinjester.gif]






































Good write-up Steve I could have used it about two months ago when I rebuilt mine.

 

[Goldwingmike]

Good pitcures, in cleaning the armature you need to use wet & dry sandpaper
also on the armature, you may have to file the very edge of the armature to get
it all even. just make sure to keep it round no flat spots. then clean out the grooves.