Doesn't look quite like the same in the instructional thread found on the forums here.

The starter in the Beast was doing the occasional CLICK thing so I purchased the plunger, contacts and brushes from the local rewinding shop for $40.00. The parts that I acquired looked exactly like the instructional thread and included the oversize contacts. I dropped the starter last night and did the tear down today. One anomaly that I noted was that unlike the existing thread my Denso had two bolts and two screws holding the end cap on the brushes end of the starter. The two bolts were the long ones that hold the two ends and main body together while the other two actually were short Phillips head screws that held the brush holder plate in place to the end piece. All went well until the brushes part of the process. The existing contacts were definitely toast with one of them being thinner that I could have ever pictured. My perception was that the brushes leads within the holder were held in place by Phillips head screws. On my Denso starter two of the brushes are soldered right onto the base plate (like the replacement holder) and the other two brushes were soldered to a ring that circled the inside of the motor housing and where these unions were made there was another braided wire that was soldered to the coils of the case. At this point I had several *** moments and since I am in no way prepared or equipped to do the kind of soldering that I envisioned I finished cleaning it all up, reassembled with the old brush set (with at least 60% still left to the good compared with the new brush set) and re-installed the starter into the Beast.

She seems to spin over with a lot more gusto now, which is a good thing. I will replace the brushes (I can pull the starter in fairly decent time) if someone out there can explain why my configuration seems to be different than the instructional. I wish I had taken some pics to explain this better. However, I am really crappy with a cell phone camera and my IED (Intermittent Explosive Disorder) was getting the better of me.

Thanks for any help on this one folks.

Cheers!

Mike

 

Kinda hard to picture what you are talking about.

See if this helps
http://www.spike.com/full-episodes/g...eason-2-ep-251

 

Th at, good Sir, was exactly the ticket. It was the process of "joining" the new brush set to the two brush wires coming off of the windings that I was stumped by. This link to the video from Powerblock answered my questions completely. Thank you for this.

Now I have to drop the starter again and finish the job.

Cheers!

Mike

 

Must of been pretty tired when I read your post last night. Read it just now and completely understood it lol Anyway glad you got it figured out

 

I was surprised to see mine soldered as well but picked up a 260 watt triggered soldering gun and did not have any problem soldering them on. Looks like the safety wire trick worked for them but it would bother me. Maybe I am getting **** in my old age.

 

Hi! I still haven't done my brush holder and intend on doing this on the weekend. Could you please tell me what type of solder (electric with flux core?) you used for your brush holder and did you solder the two wires together like shown in the video, minus the safety wire? If not, how did you go about installing your new brush holder.

Thanks, I appreciate any information that you can share with me!

Mike

 

I used electric with flux core wire and as I remember tried to remove as much of the original wire as possible so that the new wire was soldered at the original point of connection. I looked for picks but could not find any.

 

Thanks Man! I appreciate your help and quick response! Now on my to do weekend list!

Cheers!

Mike