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Disassembly and Assembly

NIPPONDENSO F4 & F8 SERIES STARTING MOTORS

Starting Motor
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F8 Starting Motor

(1) Battery terminal nut.

(3) Battery terminal.

(6) Solenoid.

(8) Switch terminal nut.

(11) Motor terminal nut.

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(12) Motor housing terminal nut.

(13) Strap.

(14) Shunt terminal nut.

(15) Shunt lead.

(17) Shift lever housing.

(18) Plunger.

(19) Shift lever.

(20) Bolts.

(21) Nuts.

(22) Rear housing.

(23) Motor housing.

(24) Screws.

(27) Brush holder terminals.

(28) Brushes.

(29) Brush holder.

(30) Armature.

(32) Drive housing.

(33) Allen head bolts.

(34) Bolts.

(36) Shift lever pin.

(37) Snap ring.

(38) Pinion drive.

(39) Armature shaft.

(40)/callout>Stop collar.

(41) O-ring seal.

(42) Index pin.

(43) Seal.

(44) Motor housing terminal.

(45) Brush springs.

(46) O-ring seal.

(49) Index pin.

(50) Studs.

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Disassemble Starting Motor

NOTE: The photographs in the Disassembly and Assembly section are of an F4 Current starting
motor. However, the basic construction is the same for the F8, F4 Current and the F4 Earlier. Any
differences are noted.

Start By:

a. remove starting motor.

1. Remove battery terminal nut (1) and washer. Disconnect battery lead (2) from battery terminal
(3). Remove screw (4) and terminal cover (5).

2. For correct assembly, make a note of the wiring connections for solenoid (6) and start relay (7).
Remove switch terminal nut (8) and lockwasher. Disconnect switch lead (9) from the switch
terminal. Remove bolt (10) and start relay (7).

3. Remove motor terminal nut (11) and washer. Remove motor housing terminal nut (12) and
washer. Remove strap (13) from the motor terminals.

4. Remove shunt terminal nut (14). Disconnect shunt lead (15) from the shunt terminal.

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5. Remove two bolts (16). Remove solenoid (6) by:

a. Pull solenoid (6) away from shift lever housing (17).

b. Raise solenoid (6) so that plunger (18) unhooks from shift lever (19).

6. Remove two bolts (20) and two nuts (21). Remove rear housing (22) from motor housing (23).

7. Remove four screws (24) and lockwashers which fasten brush leads (25) and shunt lead (26) to
brush holder terminals (27).

8. Remove brushes (28) by firmly pulling on brush leads (25). Remove brush holder (29) from
armature (30).

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9. For correct assembly, make scribe mark (31) on drive housing (32) and shift lever housing (17).
Remove six allen head bolts (33). Separate drive housing (32) from shift lever housing (17).

10. Remove four bolts (34) and lockwashers. Separate motor housing (23) from shift lever housing
(17) and armature (30).

11. Remove snap ring (35) from shift lever pin (36). Remove shift lever pin (36).

12. Snap ring (37), which is hidden, keeps pinion drive (38) on armature shaft (39). To expose
snap ring (37); use a metal cylinder (such as a pipe coupling) to tap stop collar (40) towards pinion
drive (38).

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13. Using a snap ring expander, remove snap ring (37). Remove from armature (30): stop collar
(40), pinion drive (38), shift lever (19) and shift lever housing (17).

14. Inspect all parts for wear and damage.

Assemble Starting Motor

NOTE: The photographs in the Disassembly and Assembly section are of an F4 Current starting
motor. However, the basic construction is the same for the F8, F4 Current and the F4 Earlier. Any
differences are noted.

NOTE: Replace all O-rings and snap rings with new ones. Before assembly lubricate all bushings
and pinion drive surfaces. During assembly tighten all fasteners to the specified torque.

1. Place shift lever housing (17) on armature (30). Install shift lever (19) and pinion drive (38) into
shift lever housing (17). NOTE: Shift lever (19) and pinion drive (38) are installed at the same
time.

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2. Install shift lever pin (36) in shift lever housing (17). Shift lever pin (36) passes through shift
lever (19). Install snap ring (35) on shift lever pin (36).

3. Place stop collar (40) on armature shaft (39). When installed, the beveled inside diameter of
stop collar (40) is towards the drive end of armature shaft (39).

4. Fit snap ring (37) onto armature shaft (39). Make sure snap ring (37) fits correctly.

NOTICE

Do not hit on the armature shaft when positioning the stop collar on
the snap ring (Step 5). Damage to the armature is possible.

5. Tap or pry pinion drive (38) to slide stop collar (40) onto snap ring (37). Stop collar (40) slides
and locks into position on snap ring (37).

NOTE: On F4 Earlier starting motors, stake the stop collar at three points with a punch.

6. Place motor housing (23) on armature (30). Make sure O-ring seal (41) is present on shift lever
housing (17). Align index pin (42) with motor housing (23). Install lockwashers and four bolts
(34); tighten to 17 ± 2.5 N·m (151 ± 22.2 lb in).

7. Make sure seal (43) is present in shift lever housing (17). Align scribe mark (31) on shift lever
housing (17) and drive housing (32). Install six allen head bolts (33) and tighten to 27 ± 2.5 N·m
(20 ± 2 lb ft).

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8. Place brush holder (29) on armature (30). Position it so that a grounded brush holder terminal
(27) aligns with motor housing terminal (44).

NOTE: On F8's, the brush holder ground stud aligns with the motor terminal.

9. Hold back brush springs (45) with a prying tool. Install brushes (28), with insulated brush lead
(25) towards motor housing (23).

10. Twist each set of brush leads (25) so that they overlap once and insulated brush lead (25) is on
top. Position shunt lead (26) near the appropriate grounded brush holder terminal (27).

NOTE: The brushes for the insulated brush holder terminals connect to the field winding leads.

11. Install lockwashers and four screws (24) which fasten brush leads (25) and shunt lead (26) to
brush holder terminals (27). Tighten four screws (24) to 3.8 ± 1 N·m (33.8 ± 8.9 lb in).

12. Prepare to install rear housing (22) by making sure O-ring seals (46), (47) and (48) are present
on: rear housing (22), two bolts (20) and two studs (50).

13. Position rear housing (22) so that index pin (49) aligns with motor housing (23). Install two
bolts (20) and tighten to 11.8 ± 2 N·m (105 ± 17.8 lb in). Install two nuts (21) and tighten to 9.8 ±
2 N·m (87.2 ± 17.8 lb in).

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NOTE: On F8 starting motors, one of nuts (21) is the ground terminal nut. Tighten the ground
terminal nut to 30 ± 3 N·m (22 ± 2 lb ft)

14. Prepare to install solenoid (6) by turning pinion drive (38) so that the end of shift lever (19) is
closest to the solenoid opening.

15. Position plunger (18) on shift lever (19). Install two bolts (16) and tighten to 9.8 ± 2 N·m (87.2
± 17.8 lb in).

16. Place strap (13) on motor terminals. Install washer and motor terminal nut (11); tighten to 30 ±
3 N·m (22 ± 2 lb ft). Install washer and motor housing terminal nut (12); tighten to 17.5 ± 2.5 N·m
(155 ± 22.2 lb in).

17. Place shunt lead (15) on shunt terminal (51). Install shunt terminal nut (14) and tighten to 3.8 ±
1 N·m (33.8 ± 8.9 lb in).

18. Position start relay (7) on the motor housing. Install bolt (10) and tighten to 17 ± 2.5 N·m (151
± 22.2 lb in).

19. Place switch lead (9) on switch terminal (52). Install lock washer and switch terminal nut (8);
tighten to 2.25 ± 0.25 N·m (20 ± 2.2 lb in).

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20. Position terminal cover (5). Install and tighten screw (4).

21. Place battery lead (2) on battery terminal (3). Install washer and battery terminal nut (1).
Tighten battery terminal nut (1) to:

F8 ... 30 ± 3 N·m (22 ± 2 lb ft)

F4 ... 11 ± 3 N·m (8 ± 2 lb ft)

End By:

a. Install starting motor.