Yamaha MM600D, Manual

Page: 160 / 282

154
CHAPTER SIX
Clip
Vise-grip
7.
If it is necessary to remove the brush plate lift the
plate out of the end cap including the negative brush (Fig-
ure 19). The positive brush will remain in the end cap
(Figure 20). Remove the nut and washer assembly and re-
move the positive brush assembly from the end cap.
8. Inspect the starter assembly and perform the electrical
test procedures as described under Inspection in this chap-
ter.
9. If the pinion gear was removed, install it as follows:
a. Apply low grease to the drive housing
bushing.
Install the large O-ring into the drive housing
groove.
Install the washer onto the armature shaft (14, Fig-
ure 14).
d. Install the drive housing onto the armature shaft.
Apply low temperature grease to the armature shaft
worm gear.
f. Install the pinion gear onto the armature shaft. In-
stall the spring and pinion stopper.
Using pliers, open the new stopper clip until the clip
ends are 9-10 mm (0.35-0.40 in.) apart. See
Figure
21.
Clip
Pinion
gear
0.35-0.40 in
(9-10
mm)
/
Pinion stopper
Return spring
h. Have an assistant hold the pinion stopper down and
slip the clip into the groove in the armature shaft.
Close the clip with pliers. See
Figure 22.
10. If the positive brush assembly was removed, perform
the following:
a. Install the positive brush assembly into the end cap.
Make sure the wire terminal fits properly into the
recess in the end cap (see
Figure 20). Apply sili-
cone sealant around the terminal bolt hole. Install
the
and nut.
Tighten the nut securely.
11. Apply low temperature grease to the end cap bushing.
12. Install the large O-ring into the end cap groove.
13. Install the washers onto the armature shaft (Figure
16).
14. Insert the brushes into their holders and secure the
brushes with the springs.
15. Hold the brushes back against their springs then fit
the brush plate over the commutator.