Starter Brushes? How to Install

[mikemelfa]

I found out it was worn brushes in my starter on my 25 hp 2 STROKE 1996 MOTOR, I cleaned it all up the armature and field assembly are ok and there are no cracks in he Magnets. The brushes are very worn and they are connected to a braided copper wire... I can not figure out how you would replace the Brushes? They are spring loaded and I can not for the life of me figure out how to install them without them popping out when I slide it into the cover????? DUH ????? any help The starter is a 5090983A1 and it is stamped 03-08-96 Should I even attemt this or should I just replace the starter???? Thanks MM

 

[Alumarine]

Re: Starter Brushes? How to Install

I'm not sure how these brushes are orientated but I've made tools out of plastic or cardboard to hold the brushes in until final assembly.
Sometimes paper clips work.

Cursing always helps.

 

[j_martin]

Re: Starter Brushes? How to Install

If the brushes hit the armature on the side, there is usually a small hole near the end of the brush holder where you can put a stiff wire (paper clip) to hold the brushes. If the end is sealed, there will be a tin spring thingy that holds the brushes, and is pushed out of the way by the armature and just floats or sits there harmlessly.

If the brushes hit the armature on the end, then you make a tool out of sheet metal to hold them till the end cap is nearly in place.

 

[mikemelfa]

Re: Starter Brushes? How to Install

I will try and see what I could make....

 

[merc850]

Re: Starter Brushes? How to Install

If you post a picture I have the instructions to make a tool if it applies to your motor.

 

[mikemelfa]

Re: Starter Brushes? How to Install

finally got the brushes in, was able to take the top Nut of the gear side and it simply unscrewed the gear. put in the brushes and put back together and it Still did not work... SH_T....................jut ordered a new starter. $79 & Shipping. I will save this one for parts I guess....................Thanks to everyone again.....MM