How to rebuild your starter

In this article we will be rebuilding a starter for an SR. This can be a relatively straightforward and relatively inexpensive repair, if you have the time and patience.

Skill Level 4 of 5

Time Required 25mins – 2hours.(the first time it takes longer) (not including R&I)

Tools and Equipment

-8mm, 10mm, 12mm socket

-Flathead screwdriver

-Multipurpose grease, ( for lubrication )

-Engine/Brake cleaner ( for sludge and grime )

-SOHC 89-90 KA STARTER

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Preface:  The only parts you’ll replace are the brushes at the bottom of your SR starter, and the solenoid. Clean the rest, and your starter is good as new.

1: Do not open your SR starter until you’ve completely disassembled your KA SOHC starter. That way you’ll be familiar with all the parts. Work in an open space.

2: Remove the two long 10mm bolts from the SR starter, and 2 from your solenoid. Spray and clean the Black housing section with the green sticker. Over time it accumulates grime that hinders your motor’s spinning.

Note: The head should face down because it has 4 gears that are unfastened but they’re easy to put back on. Clean them with de-greaser and liberally apply MP grease.

This is the KA head, that you won’t be using.

3:T he base of the copper core… for the electric motor is clamped in by brushes.

Note: The brushes are 4 small copper bars that press against the bottom of copper core. When you turn the key they send lots of current and spin the motor. Throughout the life of the starter they burn away and shorten, until they aren’t long enough. There’s a spring behind them to push them outward as they shorten but eventually it’s not enough.

When starters do not spin, its because these brushes have worn out. Replace them to give your starter renewed factory life.

Their plate is attached by two small Phillips screws from underneath.

4: Assemble the motor first, then replace the solenoid. The main housing of the starter, wont seal up and close properly if something is not aligned, so check everything before you tighten. I snapped a bolt by mistake this way.

5. Slide the starter pin into the new solenoid’s head and then push it back unto the U shaped spring. Make sure it snaps in, and lines up with the inset holes.

This was my starter after a rebuild, you can see the new solenoid, and new bottom cap with fresh brushes. I am very pleased with it, and its nice to know your starter will last for another 6-10 years.

Originally written by Kalypso123