Prestolite Starter Motor


Remove thru bolts (1) with washers and lockwashers (2). Remove commutator end cover (3) holding brush plate (4) in place if necessary.


End cover is marked with a double line next to the motor terminal. Also brush holder has a positioning notch which registers on the motor terminal insulator. See figure 5-28. Parts must be located correctly when reassembled.

1. Attaching stud nuts and 3. Starter shaft housing lockwashers (2) 4. Thru-bolt (2)

2. Starter motor

Figure 5-26. Removing Starter Motor




Figure 5-28. Positioning Prestolite Starter Motor Cover


Figure 5-28. Positioning Prestolite Starter Motor Cover

Figure 5-27. Prestolite Starter Motor — Exploded View

Figure 5-26. Removing Starter Motor

2. Washer and lockwasher (2)

3. Commutator end cover

4. Brush plate and holder assembly

5. Armature

6. Drive end cover

7. Drive end ball bearing

9. Terminal and brush assembly

10. Ground brush (2)

11. Frame and field coil assembly

Armature (5) and drive end cover (6) with bearing (7) are removed as an assembly. Bearing (7) is a light press fit on armature shaft and is staked in end cover (6).


To prevent brushes from escaping holders, insert a spool of slightly larger diameter than the commutator underneath brushes when brushes are half exposed as armature is withdrawn from frame. In this way armature can be reinstalled without removing brushes from holders.

Reassembly is essentially the reverse of the disassembly procedure. If brushes (9 and 10) and springs (8) have been released from holder, use clips or clamps as shown in figure 5-29 to hold them in place while installing armature. Note that drive end of frame is notched to fit drive end cover. Line up positioning notch in the brush holder assembly with terminal insulator. Line up positioning mark on commutator end head with motor terminal. Install thru bolts, tightening to 20 to 25 in.-lbs. torque.



Remove terminal nut, washer and lockwasher (1). Remove nuts and lockwashers (2) from thru bolts (3). Remove thru bolts with lockwashers (3). Remove two screws and lock-washers (4) fastening the rear cover.

Separate the rear cover (5) from the starting motor frame as follows: tap the rear cover with a soft hammer to make an opening between the rear cover and the frame. Next insert a screwdriver into the opening and push out the rear cover taking care to see that terminal and insulator (6) remain in place next to motor frame.

Lift the brushes from the commutator. As shown in Figure 5-31, pulling up the brush spring with a steel wire and pull out the brushes. Note that two negative brushes (7) have to be withdrawn slightly to be held in the brush-guide, making use of the action of the brush spring. The other two positive brushes (8) should be completely removed from the brush holder assembly (9) as shown in Figure 5-32.

Remove front cover (10), armature (11) with ball bearing (12) and thrust washer/s (13).

Figure 5-29. Using Clamps to Hold Prestolite Brushes in Place

1. Terminal nut, lockwasher and washer

2. Thru bolt nut and lockwasher (2)

3. Thru bolt and lockwasher (2)

4. Rear cover screws and lockwashers (2)

5. Rear (commutator end) cover

6. Terminal and insulator

7. Negative brush (2)

Positive brush (2) Brush holder assembly Front (drive end) cover Armature

Armature ball bearing Thrust washer Frame

Figure 5-30. Hitachi Starter Motor — Exploded View


Figure 5-31. Removing Brushes — Hitachi Motor
Figure 5-32. Hitachi Brushes and Brush Holder

Assemble starting motor in reverse order of disassembly; noting the following:

1. To determine the proper position of frame and front cover, align notch in cover with projected part of the frame.

2. After installing positive brushes in the brush holder and covering with the rear cover, align and fasten the brush holder to the rear cover with screws and lockwashers from the outside of the rear cover.

3. Thru bolt nuts should be tightened to 20 to 24 in.-lbs. torque.

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