Starter Inspection - Yamaha V star 1100 Owner's Manual

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16. Install the gear plate (Figure 25) so its cutout
engages the notch in the armature housing. Make
sure the flat side faces out and seat the plate (A, Fig-
ure 40) in the armature housing.
17. Lubricate a new O-ring with lithium soap
grease, and install it onto the armature housing (B,
Figure 40).
18. The front end cap has four machined slots (A,
Figure 41) around its inner circumference. The lo-
cating key (Figure 20) must be installed in the one
slot that sits opposite the cutout (C, Figure 40) in
the armature housing when the front end cap is in-
stalled. Identify that particular slot and install the
key as follows:
a. Temporarily fit the front end cap onto the ar-
mature housing.
b. Align the index mark on the end cap (Figure
42) with the mark on the housing.
c. While keeping the index marks directly oppo-
site one another, carefully slide the front end
cap straight off the housing until the cutout in
the housing is exposed (C, Figure 40).
d. The slot in the end cap that is aligned with the
housing cutout receives the locating key.
e. Remove the front end cap and install the lo-
cating key (Figure 20) in the slot identified in
substep d.
19. Install the front end cap onto the housing so the
index mark on the cap aligns with the mark on the
housing (Figure 42).
20. Install the starter case bolts (Figure 19). Apply
a medium-strength threadlocking compound to the
bolt threads and tighten the bolts securely.
21. Lubricate a new O-ring (A, Figure 17) with
lithium soap grease and install it onto the front end
cap.
22. Install the inner snap ring onto the armature
shaft.
23. Install the starter gear (C, Figure 17) onto the
armature shaft and install the outer snap ring (B).
Inspection
NOTE
The O rings, case bolts and brush
holder assembly are the only starter
components available.
1. Pull the spring away from each brush and pull
the brush out of its holder. Measure the length of
each brush with a vernier caliper. If the length of
40
41
42
any brush is less than the service limit in Table 1,
the brush holder assembly must be replaced. The
brushes cannot be replaced individually.
2. Inspect the commutator (Figure 29). The mica
in a good commutator sits below the surface of the
copper bars. Measure the mica undercut, which is
the distance between the top of the mica and the top
of the adjacent copper bars (Figure 43). If the mica
undercut is less than specification (Table 1), have
the commutator serviced by a Yamaha dealership or
electrical repair shop.
CHAPTER NINE