Install Drive End Cap; Starter Motor Service Models 540000, 610000; Starter Solenoid - Vanguard OHV V-Twin User Manual

1. Push down on armature and brush end cap.
2. Slide starter housing (1) over armature (2),
aligning notch with insulated terminal.
NOTE: Use care to prevent damage to magnets in
starter housing.
Fig. 27

Install Drive End Cap

1. Assemble spacer washer (1) and spring washer
(2, if equipped) to armature shaft, Fig. 28.
2. Assemble drive end cap (4) to armature shaft.
3. Align mark on end cap with mark on housing.
4. Install thru bolts (3). Torque to 50 in. lbs. (6 Nm).
5. Spin armature to check for binding. Correct any
binding.
6. Install starter drive.
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Fig. 28
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STARTER MOTOR SERVICE
Models 540000, 610000
Remove Starter Solenoid
1. Remove nut and field coil wire from stud
terminal.
2. Remove solenoid mounting nuts and solenoid
3. Lift solenoid to disengage drive lever from
plunger, Fig. 29.
NOTE: Hold starter in vertical position with drive
housing side DOWN when removing and
installing solenoid.
Fig. 29
Install Starter Solenoid
4. Engage flats on plunger (1) with fork in drive
lever (2) and assemble solenoid to starter,
Fig. 30. Torque nuts to 70 in. lbs. (8 Nm).
5. Install field coil wire and nut. Torque nut to 90 in.
lbs. (10 Nm).
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Fig. 30
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