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Intro:
Overhauling the starter motor is not that difficult and hopefully the step-by-step process IÔÇÖve outlined below will make it as straightforward as possible. The first step is to decide whether you want to just clean the starter commutator or if you want to replace the brushes as well. I found that replacing the brushes was relatively inexpensive and did not involve much extra work so thatÔÇÖs what IÔÇÖve outlined in this DIY article. The part numbers I ordered are as follows:
12411459445 (O-rings)
12411459567 (Brush connected to ground wire nut)
12411459297 (Brush plate)
Steps:
Locate starter motor
Remove and disassemble starter motor
Clean/overhaul starter motor
Reassemble and install
Supplies needed:
Replacement brushes and misc. parts
Brake cleaner
Scrub pad/wash cloths
Last edited by mnbikerguy; 05-24-2011 at 11:58 AM.
Put your bike on the center stand, lift up the seat and pull out the storage compartment/fuel injector module. Pic 1 was taken after step 1 was completed. Notice the two red arrows IÔÇÖve added to the picture. They point to the two mounting bolts on the starter motor (near the left side of the battery).
Last edited by mnbikerguy; 05-24-2011 at 02:39 PM.
Remove the battery, which will give you access to the starter motor. Pic 2 was taken after the battery was removed. Notice the two red arrows IÔÇÖve added to point out the two mounting bolts on the starter motor. Also notice the plastic cover outlined in blue which partially obscures the starter motor.
Last edited by mnbikerguy; 05-24-2011 at 02:40 PM.
Remove the three bolts holding the plastic cover in place on the left side of the bike and pull it back to fully expose the starter motor. Pic 3 shows the three bolts on the plastic cover. The same cover can been seen from a different angle on Pic 2, again outlined in blue.
Last edited by mnbikerguy; 05-24-2011 at 02:41 PM.
Pull out the starter motor. This can be a little tricky, you might need something like a rubber glove that gives you a better grip on the starter motor as it took a bit of pulling for me to get it out. Pic 5 shows what it looks like after the starter motor has been removed.
Last edited by mnbikerguy; 05-24-2011 at 02:41 PM.
