Reassembly - MerCruiser GM4 Service Manual

Reassembly

After all parts are thoroughly tested and inspected
and worn or damaged parts replaced, reassemble
starter as follows:
1. Assemble brushes and related parts to field frame
as follows:
a. Assemble brushes to brush holders. Attach
ground wire to grounded brush and field lead
wire to insulated brush.
b. Assemble insulated and grounded brush
holders together with V-spring. Position as a
unit and install support pin. Push holders and
spring to bottom of support and rotate spring
to engage center of V-spring in slot in support.
2. Assemble over-running clutch assembly to arma-
ture shaft as follows:
a. Lubricate drive end of armature shaft with
SAE 10 oil.
b. Slide assist spring and clutch assembly onto
armature shaft with pinion outward.
c. Slide retainer onto shaft with cupped surface
facing end of shaft (away from pinion).
d. Drive snap ring onto shaft and slide down into
groove.
b
a - Snap Ring
b - Groove
Index
4A - 16 - STARTING SYSTEM
e. Assemble thrust collar on shaft with shoulder
f.
3. Place 4 or 5 drops of light engine oil in drive hous-
ing bushing. Slide armature and clutch assembly
into place while engaging shift lever with clutch.
4. Position field frame over armature and apply
Quicksilver Liquid Neoprene between frame
against drive housing, observing caution to pre-
vent damage to brushes.
5. Place 4 to 5 drops of light engine oil in bushing in
commutator end frame. Place brake washer and
commutator end frame onto shaft.
6. Install solenoid return spring on plunger.
7. Position solenoid assembly to starter motor end
frame and turn solenoid to engage flange in slot.
8. Install (and tighten securely) screws which hold
solenoid assembly to end frame.
9. Secure starter motor connector strap terminal
with screw and washer.
a
72073
next to snap ring.
Place thrust collar and retainer next to snap
ring and using two pliers squeeze both until
snap ring is forced into retainer.
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