Steel Pinion Style; Starter Motor Service - Except Models 540000, 610000; Dissembly - Vanguard OHV V-Twin User Manual

Assemble
1. Assemble clutch drive (5) to starter shaft. Rotate
clutch until it drops into place, Fig. 11.
2. Install pinion gear (4) with beveled side of teeth
UP.
3. Install washer (3) and retainer (1).
4. Install NEW roll pin (2).
NOTE: Slot in roll pin should face up.
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Fig. 11

Steel Pinion Style

Disassemble
1. Grasp end of rubber dust cover (1) and pull to
remove, Fig. 12.
2. Push down on upper spring retainer (3) to
expose retaining ring (2) on shaft.
3. Use a small screw driver and pry off retaining
ring. Discard retaining ring.
4. Remove upper spring retainer, spring (4), lower
spring retainer (5), pinion gear (6) and clutch (7).
Inspect
Check pinion gear for damaged or worn teeth.
Rubber bottom of pinion is part of clutch. Check for
wear or damage. Check clutch for wear.
If clutch rubber inside of pinion gear is worn or
damaged, pinion gear will slip when starter is
engaged.
Assemble
1. Lubricate helix (8) with a light coat of grease.
2. Assemble clutch and pinion gear to shaft.
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3. Assemble lower spring retainer with OPEN END
UP.
4. Install spring.
5. Install upper spring retainer with OPEN END UP.
6. Compress spring. Install NEW retaining ring to
shaft.
7. Compress retaining ring with pliers to ensure
that it is seated properly in groove in shaft.
8. Pull up on upper spring retainer until retaining
ring snaps into groove in upper spring retainer.
9. Push dust cover down until it snaps into groove
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in lower spring retainer.
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STARTER MOTOR SERVICE
Except Models 540000, 610000
Disassemble
CAUTION: DO NOT clamp motor housing in a vise
or strike with a hammer. Starter motors contain
ceramic magnets that could be broken or cracked
if the housing is damaged.
The disassembly and inspection procedure of the
two starter motors is similar. Where a procedure or
specification is different, those differences will be
shown. See Fig. 13 (radial compression brush
spring) or Fig. 14 (axial compression brush spring)
for exploded view of the two starter motors. Scribe
a mark on drive end cap and starter housing for
alignment purposes when reassembling.
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Fig. 12