Valeo starter overhaul - three counties moto guzzi club home page
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1. in the grove as possible slide the thrust washer up to the wire ring and use a good set of pump pliers to squeeze between the end of the shaft and the thrust ring It is definitely going to go one side then the other so don t try to bring it up evenly Get it set up so that the gap in the wire ring is facing away from where you are applying the pliers and that the wire ring is deepest in the groove at the same spot where you are applying the pliers Now squeeze like stink The whole thing will just pop together This is sometimes a bitch of a part to reassemble If you go to a Starter alternator rebuild shop they should be able to get it back on for you As HoboMatt has said in the past sometimes they will do it for free just because you gave them something interesting and new to look at work on It s not every day that a person gets to fiddle with a BMW motorcycle starter hadn t thought of it before but you may be able to use a small vise as a press instead of the jaws of a pair of pump pliers As you squeeze with the vise you could use a small punch and hammer to help knock the wire ring into place inside the thrust washer With that tough part out of the way all that remains is lubricating the starter s main shaft and bushing in the head and reassembling the head to the starter Before reinstalling the starter it s nice to clean out the starter motor cavity My GS had all kinds of sand and grit collected in there plus oil fr2. ratio of 5 5 1 and the 55 is 5 6 1 However these parts are not likely to fail The motor housing and the brush assemblies are identical as is the solenoid switch plunger fork and spring The same rebuild kit bushing thrust ring circlip and brush repair kit will work on both The bolt kit used on the 55 if you want to replace the T25s with allens will not work on the 15 because one of the 55 bolts is shorter Replacement The D6RA15 has been renamed by Valeo to 432586 This is available from Ace Houston Warehouse for 155 to 175 depending on quantity Contact Bob Spencer 800 392 3332 acehoutx flash net and be sure to quote the Airheads Club account 700 to get the discount Parts not available from the dealer might be available from Tiedemann Auto Elektrik in Germany Other Valeo Starter repair links that referred to for this Greg Feneis article on the Airheads site concentrates on electrical problems Alex s page look under Technnical Stuff concentrates on broken magnets WSC Airheads Beemer Club An international motorcycle club tor unpretentious owners of air cooled BMWs Valeo Starter Troubleshooting Disassembly and Re assembly Greg Feneis 4290 The chances are very good that your starter problem is relatively cheap and easy to fix Perhaps your starter has the same symptoms as stated below If not you can still check things out with the part marked Testing and once a problem is isolated the re
3. 96 69 94 1360 CITROEN AX ZA _ 1 4 GTi 06 91 12 92 74 100 1360 CITROEN BX XB _ 11 10 88 06 92 40 55 1124 CITROEN BX XB _ 14 01 89 12 89 47 64 1360 CITROEN BX XB _ 14 09 85 02 93 49 67 1360 CITROEN BX XB _ 14 04 83 07 89 52 71 1360 CITROEN BX XB _ 14 04 83 02 93 53 72 1360 CITROEN BX XB _ 14 01 89 02 93 55 75 1360 CITROEN BX XB _ 19 D 09 83 12 87 47 64 1905 CITROEN BX XB _ 19 03 87 02 93 51 69 1905 CITROEN BX Break 14 01 89 12 89 47 64 1360 CITROEN BX Break 14 01 89 02 93 55 75 1360 CITROEN C15 VD _ 1 1 1 07 88 12 96 44 60 1124 CITROEN C15 VD _ 1 4 E 05 87 12 96 44 60 1360 CITROEN C15 VD _ 1 4 07 87 12 96 49 67 1360 CITROEN C15 VD _ 1 4 1 05 91 12 96 55 75 1360 CITROEN ZX N2 1 4 03 91 06 97 55 75 1360 205 I 741 1 0 02 83 10 87 33 45 954 205 I 741 A C 1 1 02 83 10 87 37 50 1124 205 I 741 A C 1 4 02 83 10 87 44 60 1360 205 I 741 A C 1 4 10 85 10 87 58 79 1360 205 I 741 A C 1 4 02 83 10 87 59 80 1360 PEUGEOT 205 I Cabriolet 741 20D 1 1 CJ 10 89 12 94 44 60 1124
4. Except for the parts under the commutator cover the other parts are not usable without modifications Order a new Valeo electric starter from Ace Houston Warehouse Contact Bob Spencer at 1 800 392 3332 Part number D6RA 15 now lists as 432586 Price in August of 2001 172 50 plus shipping I ordered one of these units as a spare It appears new but it failed to carry the usual Valeo aluminum foil sticker EuroMotoElectrics also carries Valeo starters Wheel Balancer and Adapter Photos and write up to follow Speed versus RPM Spreadsheets CLAMP HERE ie ver alle 1 x 1 x 6 PINE Motor Housing Starter Motoren von Valeo Astra Clio Corsa B Wichtig ist nur die Startermotorbezeichnung DR6A Astra F 74KW Renault Clio Phase 1 55 KW silber blau 1 4 1 und die Liste Nur Motor ohne Planetengetriene und Schubschraubtrieb D6RAS Der Anlasser pa t bei Bezeichnung Bezeichnung Bezeichnung Baujahr kW PS ccm CITROEN AX 7 10 12 86 12 88 30 41 954 CITROEN AX ZA _ 10 07 86 12 98 33 45 954 CITROEN AX ZA _ 11 12 86 06 90 40 54 1124 CITROEN AX ZA _ 11 KAT 09 88 12 89 40 54 1124 CITROEN AX ZA _ 11 10 89 12 97 44 60 1124 CITRO N AX ZA _ 1 3 Sport 04 87 12 88 70 95 1294 CITRO N AX ZA _ 14 12 86 12 88 44 60 1360 CITRO N AX ZA _ 14 06 88 12 89 49 67 1360 CITRO N AX 7 14 04 87 04 97 55 75 1360 CITRO N AX ZA _ 14 01 88 12 92 62 85 1360 CITRO N AX ZA _ 1 4 GTi 06 91 12
5. VALEO REPARE LIST OF COMPATABLE DONER STARTER MOTORS VALEO REPARE INSTRUCTIONS Valeo starter overhaul Valeo starter overhaul If your Valeo starter makes a screeching noise after starting the engine it needs to be cleaned Other symptoms of starter trouble vary but inevitably the starter needs to be pulled apart for cleaning and inspection If your starter has an electrical fault not working intermittent operation etc read Greg s article linked at the bottom of the page If your starter has loosened magnets read Alex s article Contrary to what I ve read the web don t think the squealing problem is caused by the planetary gears as much as by the solenoid mechanism plunger and pinion splines For reference here are the internal parts names used and replacement availablity from BMW for the D6RA15 starter used on Airheads BMW does not list any repair parts for the D6RA55 starter used on the Oilheads but the brush sets and repair kit 4 will work Differences are listed at the bottom of this page At the time of writing this replacement pinions brushes solenoids etc were available from BMW Pinions and solenoids were about 120 and brushes were 10 to 20 depending on which kit you need 1 Solenoid switch 12 411 244 607 2 Clutch fork lever 12 411 244 609 3 Starter pinion 12 411 244 682 4 Repair kit 12 411 244 611 5 Carbon brush set 12 41 1 244 684 Valeo starter overhaul To
6. aped sheet metal cover You should be able to take a utility knife and work it up little by little When first looked at that cover thought that it wasn t coming up without destruction with all of those little cleats holding it in place After the cover 16 off take the snap ring and shim off of the main starter shaft and the shaft should slide right out So now you have the backing plate with big plastic ring gear in one hand and the main shaft with planetary gear set in the other Clean all the waxy grease up like using mineral spirits and a scrub brush rubber gloves too because it all washes up nice in the laundry tub with hot water when I m done Getting the parts hot in the hot water helps them to dry faster and more completely Re grease and re assemble the main starter shaft and planetary gear set to the cover plate ring gear install the snap ring and put the donut shaped sheet metal cover for the planetary drive back on To service the motor brushes and armature end bearing take off the two copper end nuts and remove the sheet metal cover There 15 a rubber gasket for the cover so work it up like a champagne cork Push up with your thumbs a little rotate push up rotate etc With the cover off you will see a neat method of commutating an electric motor Axially There is a fiberglass biscuit between each spring leg and each brush Don t loose them as they help keep the spring legs from digging into the soft bru
7. asy if you relieve the spring pressure from the pivot point the pin should drop out Now the solenoid slug lever and bendix should all come out together The spring should stay on the solenoid slug by its self If you take it off for cleaning be sure to put it back on the way it came off One end of this spring is kinked to help hold it in place on the slug If you put the kinked end at the wrong end of the slug then the miss installed spring will hang up the mechanism Remove the pop rivets that hold the cover plate to the main starter body 2 rivets found it easy enough to stick a small punch into the center of the rivets and wag the punch around like I m stirring coffee The punch works with the edge of the hole in the plate to sheer off the rivet head Don t worry about replacing the rivets they are handy in the factory for holding partial assemblies together but are not necessary for our uses Next if you have not already done so remove the nut holding the motor terminal to the bottom of the two large copper studs on the back of the starter solenoid When you separate the cover plate from the motor you should have the plate and the main starter shaft and planetary gear set in one hand your other hand will be the motor case and brushes and armature Don t expect the armature to come out of the motor case It is held in place by a snap ring later To get at the planetary gears you will have to pluck out the donut sh
8. ch at the bottom of the solenoid cylinder is so worn that even when the slug bottoms out in the cylinder the switch is not energizing the starter motor 4 The solenoid slug s return spring is either broken or installed wrong up side down 5 The solenoid and starter drive gear are working correctly and there is a loose connection at the two large terminals main battery cable at the top terminal short starter cable at the bottom terminal on the end of the solenoid or there is a problem WITHIN the starter motor Testing Testing for some combination of 1 2 3 or 4 When the starter is failing as in the above scenario take the starter cavity cover off of the top of your engine don t know what this entails for your bike but on my GS found that only had to remove the gas tank to get access to the top cover of my engine Connect a test light between the two large terminals on the starter solenoid The light should light This indicates that at that point the starter s main cable is getting power to the starter This also indicates that the starter motor completes a circuit to ground and should work when if energized Press the start switch You should hear feel some activity from the starter solenoid If the solenoid does make a noise and the starter motor does not operate and the light does not go out then your problem is more likely 1 2 3 or 4 above Results indicating 5 If you press the start switch and you h
9. cylinder are corroded or damaged corrosion can be cleaned up to temporarily restore operation but once corrosion starts happening you can bet it will return to screw you when you least expect it 2 There is an open circuit in the electromagnetic coil 3 The high capacity switch that energizes the starter has failed or only works intermittently Note Bendix Starter drive gear with sprag clutch assembly The bendix lever and solenoid slug will all come off easy if you get the thrust ring off of the main starter shaft first Before you remove the thrust ring see thrust ring installation near the end so you know ahead of time how fun it will be to put this back together To remove the thrust ring you ll have to knock it toward the bendix remove a wire ring and then take off the thrust ring To do that first protect the bottom of the starter with two wood blocks don t want to damage the parts at the tail of the starter Next find a deep socket whose inner diameter is just larger than the main shaft and whose edge lines up with the thrust washer nicely Place the socket on the end of the shaft and give ita whack with a hammer This should knock the outer thrust ring back toward the bendix What should remain is a wire ring in a groove on the shaft Work the wire ring off it will get distorted but don t kill it then the thrust washer can come off Push the lever s pivot pin out with your fingers It s quite e
10. d find a friend with a lathe and have him do a facing operation to restore that surface Then you certainly want to dig the copper filings out of the gaps between the segments Grease up the shims and washer on the amateur side the bushing in the motor case and the shims or washers on the clip side and reassemble Be careful not to go wild with the grease because you don t need to get grease on the comutator or brushes Once you put the clip back on the shaft securing it in place you can put a little extra grease in the cover before you slip that back into place Support the motor case on it s front end so you can work on the brush end without holding it Two wood blocks will leave a gap for the armature shaft protruding slightly from the front Otherwise gently trap it in a vise or some other holding method Put the plastic brush holder on and insert the brushes into their slots Properly route each brush s wire and position their terminals Put the nuts and washers on their studs to hold the plastic brush holder on the end of the motor case Install the fiberglass insulators Install the spring by first starting each leg on the back of each brush s insulator just on the edge then get the center portion of the spring that points toward the armature started on it s little ramp While maintaining the legs in place on the brushes push down on the spring s coils and the center portion of the spring will lock in place with two cl
11. ear feel some activity from the starter solenoid and the motor does not go yet the light DOES goes out then your problem most likely is 5 above less likely What if the solenoid is quiet If you press the start switch and you hear feel nothing from the starter solenoid then you need to test if the solenoid s electromagnetic coil is connected and getting voltage from the starter relay when you press the start switch Connect the test light between the small terminal on the starter solenoid leaving the wire plugged into it and the body of the starter and press the start switch again If the light fails to light while pressing the starter switch then move the test lead connected to the starter body to a known good ground and press the start switch again If the light lights when connected to a known good ground but not when connected to the starter body then the starter is not properly grounded rare If the test light fails to light while connected to the small terminal of the starter solenoid in either of the two grounding conditions then the solenoid is not getting power from the starter relay If the starter solenoid is getting power but is not making any noises chances are good that the electromagnetic coil in the solenoid is bad To repair 1 2 3 4 or 5 see the disassembly re assembly guide below Problems with in the starter motor 5 motor fails to run or runs poorly even though battery and main connections a
12. four magnets within the motor housing Each magnet is held in place within the motor housing with an adhesive The symptoms during starter engagement are the faint sound of the solenoid engaging instrument lights going from full bright to dim and when measured the voltage across a healthy battery dropping to approximately 8 5 volts indicating a high current draw due to the stalled electric starter Although a rebuild kit and other parts are available individual parts within the motor housing and planetary gear housing are not available separately from BMW These latter two units are sold as an assembly Separate Valeo parts are available from Tiedemann Auto Elektrik in Germany Parts Listing Price Listing You can also get complete Valeo starter motors and individual parts from EuroMotoElectrics Following the directions in the BMW factory shop manual disassemble the Valeo electric starter completely until you are left with the starter motor body and armature assembly Remove the nuts and washers holding down the commutator cover The brush holder is made out of bakelite material that chips and cracks easily so be gentle while performing the following steps Lift the end of the brush spring and remove the fiber insulators and brushes Release the brush spring gently I find using a strong string to form a loop works well in lifting the end of the spring Remove the brush spring from the brush holder The brush spring extends through the bakel
13. icks One click for when the spring s center portion passes the end of the plastic ramp and the other for when it engages the hole for it in the motor case When reinstalling the sheet metal cover over the end of the starter be sure that the rubber bumpers and insulators are in place You don t want those misplaced or left out and have the starter s main power lead ground against the motor case Put the motor back together and the cover plate with the planetary drive back on the motor The now clean solenoid should be mounted back on the cover plate and the solenoid slug lever bendix should be reinstalled with its pivot pin You are now ready to put the head back on but first Thrust Ring Installation There is one remaining difficult part you have to get the thrust washer that the bendix hits when the starter engages back in place on the main shaft Put the thrust washer on the shaft flat side of the washer faces the drive gear internal tapered part faces the wire ring and groove Put the wire ring back in place on the groove of the shaft You can squish the wire ring and work it into the groove as best you can so it s outer diameter is minimized using pump pliers or such the shaft is pretty hard material so don t worry too much about catching it in the pliers jaws You will never get the wire ring squished tight to the shaft so all that squishing effort will only go so far After the wire ring is made to fit as tightly
14. ite brush holder and clips itself to the motor housing Removal of the brush spring can be tricky so take your time Remove the brush holder and rubber gasket Some Valeo starters came with a metal cup pressed over the end of the motor bushing This cup retains grease and keeps contaminants out Use a small flat bladed screwdriver and carefully pry the metal cup off the bushing Remove the E clip at the end of the armature Make sure that you do not stretch the E clip if you do get a new one at a fastener supply store Take note of the location of washers shims and any other parts The solid spacer is located between the armature and the motor housing The shims are located on the outside of the motor housing Drill out the two pop rivets that hold the planetary gear housing and the motor housing together Remove the planetary gear housing Remove the armature from the motor housing Wash out the planetary gears and housing with solvent to remove all traces of old grease This is best performed while the planetary gear housing is immersed in solvent and the shaft is manually spun Repeat until thoroughly clean then let dry Thoroughly grease the planetary gears and cavity within the planetary gear housing Clean the commutator bars on the armature using a fine Scotch Brite pad or similar product Wipe down the cummutator bars with contact cleaner In the photo above note the remaining black strip of magnet material still attached to the moto
15. maining portion covers disassembly and re assembly of the Valeo Reviewing the symptoms The starter operates correctly most of the time When the starter does operate the engine is cranked over at a reasonable speed and it does not appear that the starter motor is struggling as if the battery is nearly dead When it does fail you still hear a clicking noise every time you press the starter switch This clicking noise is a rather strong sound from under the starter cavity cover not to be confused with a small clicking noise which is the starter relay Most of the time when it is failing several successive starting attempts will get the starter motor to eventually operate If the above wordy sequence is true your problem most likely has to do with the starter solenoid rides piggyback on the starter motor Perhaps first some explainin When you press the starter switch and all the right conditions are in place e ignition key on clutch pulled in and or trans in neutral etc a small relay is energized When this relay turns on the starter solenoid is energized The starter solenoid is an electromagnet that attracts a barrel shaped slug into a cylinder The starter solenoid serves two functions for the starter 1 The action of the solenoid does most of the work with engagement disengagement of the starter s drive gear with the gear teeth on the engine s flywheel When the solenoid is energized its slug works agai
16. mating surface of the magnet and the mating surface of the motor housing You will want to apply enough adhesive to fill any gap between the magnet and the motor housing This part is tricky as the magnet tends to wander while trying to insert it into the motor housing Install the magnet in place Install a plastic spacer on each side of the magnet that is being reattached Slide the magnet to the proper depth based on adjacent magnets Apply the clamp shown below and let the adhesive cure at least 24 hours You may temporarily remove the plastic spacers and wipe off any excess adhesive from around the magnet edges Replace the plastic spacers until the adhesive has cured If all four magnets have separated you will have to determine which magnet went where You cannot bond the magnets in a random order Reassemble the motor in the reverse order using new pop rivets Sparingly lubricate the bushings with grease This is a view of the magnet Note the missing material on the mating surface which can be seen in the photo above The motor housing is roughly the size of a soft drink can making it impossible to use a conventional clamp to hold the magnet in place while the adhesive cures I made this arrangement to clamp the magnet in place The soft pine wood strips also add a cushioning effect while the clamp is tightened down Other options Purchase a used Valeo electric starter off of a Saturn vehicle The motor housings are identical
17. nst a spring to move into the cylinder The slug is linked to the starter drive gear through a lever and so causes the starter drive gear to move toward the flywheel When the solenoid is no longer energized the spring causes the slug to move back to its rest position which retracts the starter drive gear from engagement with the gear teeth on the flywheel 2 At the bottom of the solenoid s cylinder is a high Capacity momentary switch This switch is used to energize the starter motor This switch is turned on when the slug completely bottoms out in the cylinder So you have the solenoid energizing attracting the slug to the bottom of the cylinder The movement of the slug causes the drive gear to engage the gear teeth on the engine s flywheel Once the slug gets to the very bottom of the cylinder and hits that switch the starter motor is energized and starts to turn one would hope This whole mess is a sort of mechanical interlock that prevents the starter motor from running until the starter drive gear is fully engaged Clue In the case of a bike having the above mentioned symptoms chances are good for one or more of the following conditions 1 The solenoid slug and cylinder are dirty gummed up corroded etc preventing complete bottoming out of the slug to actuate the heavy switch at the bottom 2 The starter drive gear and or lever are binding gummed up etc preventing bottoming of the slug like above 3 The swit
18. of solvent and blow dry with compressed air You may want to lube with a VERY thin coat of a moly based grease such as CV joint grease By removing the large circlip and prying the cover from the planetary gear housing you can slide the gears out a bit in order to clean them better Flush the gears with solvent and brush away all of the old grease that you can reach Pack the gear housing with fresh grease you don t need to use a lot slide the shaft through push the cover into place and reapply the large circlip Disassembling the starter shaft If you want better access to the planetary gears or the pinion splines you will need to remove the thrust ring from the end of the starter shaft as follows With a socket or equivalent drive the outer ring down from its internal snap ring towards the pinion In this picture am using an item from a BMW toolkit to push it down Pry the snap ring away GENTLY you may need to reuse it and slide the thrust ring and pinion off the shaft Remove the large external circlip from the base of the starter shaft and slide the shaft out through the planetary gearbox Reassembly is difficult at this point After putting the retainer and the snap ring back on the shaft you will need to push down HARD on the retainer and simultaneously squeeze the snap ring under it The retainer and snap ring are partof the rebuild kit listed by BMW but in truth see very little advantage in removing the
19. ols needed Basic disassembly process 6 Spring washer 12 41 1 244 623 7 Hex nut 12 41 1 244 622 8 Repair kit screws 12 411 244 613 9 Carbon brush set 12 41 1 244 685 25 or 4mm allen for removing the three motor housing bolts Torx T20 for removing the solenoid switch 13mm wrench for removing the solenoid lead 8mm wrench for removing the brush assembly Remove the nut and washer holding the brush cable to the solenoid body Remove the three bolts holding the motor housing to the nose casting and remove the T20 bolt holding the solenoid to the casting The nose casting can be pulled away and the motor body can be pulled away as well leaving three basic parts the casting the motor body and the steel plate frame Note there are weak rivets also holding the motor housing to the plate but pry them apart and discard them Remove the remaining two T20 bolts so you can pull the solenoid switch and spring off At this point you can slide the pinion towards the end of the shaft and remove pin holding the fork and plunger in place it will probably fall out Clean the plunger and the inside of the solenoid switch body Valeo starter overhaul If you are just trying to stop a run on squeal you may not need further disassembly By cleaning out the curved splines between the pinion and the starter shaft and cleaning the plunger you can restore free operation Be sure to flush with plenty
20. om a leaky hose port which was poorly blocked off apparently part of the Shed system which was later removed and seeping oil This oil seepage covered the floor of the starter cavity and worked its way to the starter cavity drain hole 4mm hole in the side of the engine adjacent to the dip stick and made an ugly mess of the side of my engine When reinstalling the starter it might be nice to run a few tests before completely buttoning everything up Install the starter and reconnect the electrical connections Disable the ignition so that the engine will not start and test the starter for proper operation With a fully charged room temperature battery in good condition you should be able to go through 15 or 20 cycles of 30 seconds of cranking followed by 10 seconds of rest While testing listen for improper noises etc Directly after several cycles of testing test for poor main battery connections by using your fingers to feel for toasty warm connections on all of the main cables After serious cranking tests a main battery connection that gets warm indicates a poor connection Good luck with your starters Valeo Starter Rebuild This rebuild deals with one of the most common forms of failure of the Valeo electric starter namely separation of one or more of the motor magnets from the motor housing When this occurs the magnet attaches itself to the armature making it impossible for the starter motor to rotate There are
21. r housing 1 removed all traces of the remaining magnet and adhesive from the motor housing This required effort as the adhesive did not break down with the application of acetone or lacquer thinner The adhesive was most probably an epoxy Fabricate two spacers made from plastic sheet so that they fit snugly between the magnet that is being reattached and the adjacent magnets that are in place This will locate the magnet correctly while the clamp is applied Thoroughly clean the mating surface of the motor housing with emery cloth or if you have the facilities glass bead the inside of the motor housing to create a textured finish for the adhesive to cling to Wipe down the area with acetone or lacquer thinner to remove all traces of oils Thoroughly clean the mating surface of the magnet with acetone or lacquer thinner to remove all traces of oils I used high temperature epoxy to bond the magnet to the motor housing after the first failure This lasted four years until the magnet separated from the motor housing again There are other dedicated products such as Loctite 325 SpeedBonder Loctite 707 Activator This product is advertised to bond magnets on motors designed for extreme environments withstands a temperature of up to 325 degrees F and has a gap fill capability to 0 040 J B Weld is another possibility I can t comment on the latter two products since I haven t had the chance to test them Apply a thin coat of adhesive to both the
22. re good A problem internal to the motor could be a bad or worn brush or broken brush spring or burnt segments on the commutator not likely or loose permanent magnets in the motor case stationary magnetic field that the armature works against Legend has it that the epoxy that holds these magnets in place and away from the armature has been known to fail When this happens the stationary magnetic field that the starter depends on is reduced and the magnets drag on the armature and may break up into bits think covered all conditions relating to the starter motor and its connections If you have any questions or if left out anything just drop me a line or two Valeo Starter Disassembly and Re assembly The procedure below covers a Valeo starter from a 91 R100GS perhaps yours is similar Please read this article from start to finish to get an idea of what kind of work and tools will be required This description is for a Valeo starter The Bosch starter 15 quite different The Valeo uses a permanent magnet DC motor One of the benefits of this type is that you can really abuse it operate near stall speed etc and it will usually take it and not get too hot The down side 16 that compared to a series wound DC motor it does not develop super duper torque at stall or near stall speeds so it needs a reduction gear to compensate think the Valeo uses a 5 1 reduction planetary gear set besides the starter gear to fl
23. se parts at all because you can clean the parts well enough without it The remaining disassembly you can do is removing the brushes found this to be somewhat tedious and the brush holder assembly is fragile By removing the two nuts on the end of the motor you can pull the cover off and inspect the brushes and contacts If you have had no problems and the contacts and brushes look OK absolutely would not go any farther If the contacts look badly arc damaged or the brushes look too short you will need to carefully study Greg s article before proceeding If you do a total disassembly of the starter this is what you are likely to end up with the solenoid body and nose casting are not shown j nere Some people prefer the Bosch starter instead Greg s article below describes the basic differences in design The Valeo is much lighter about 2 8kg instead of 4 5 for the Bosch Differences between D6RA15 and D6RA55 Valeo starter overhaul Although the starters are very similar in construction they turn in different directions because they are mounted facing in different directions on the bikes So the pinion and shaft differ in the direction of the splines and gear faces and the commutator is wired differently Of course the nose casting is different and the reduction gear teeth are coarser on the 55 which makes every part in the drive line commutator gear housing carrier shaft pinion different The 15 has a reduction
24. sh material and they act as an insulator Lift each spring leg and flip it to the side to remove and inspect the brushes Once the brushes are out it s easier to remove the brush spring with a narrow pointy tool like a pick Simply help the center portion of the spring up over the notch in the motor case and the ramp shaped area of the plastic brush holder Take care when doing this as it is easy to crack the brush holder You can now grip the shinny center bearing cover with a pair of pump pliers and slowly work it upward and off It is a thin sheet metal cover so don t squish it dead Pop the snap ring off of the end of the shaft and keep track of the shims and washers some are on the snap ring side of the bushing some are on the armature side Now you can remove the armature from the motor case Clean up the motor case and armature Look for signs that one or more of the 4 permanent magnets have been dragging on the armature or is loose or is coming loose from the motor case My armature looked like the shellac was chipping off from not being applied right but there were no scraping marks You can use a sewing needle or pick to dig out the crap from between the comutator segments Don t dig too deep If you dig too deep and the width of the tool is too wide you can distort the edges of the segments If this happens you will get some fast brush wear and crappy operation If the segments are in bad shape pitted or burned you coul
25. ywheel gear reduction The Bosches are probably series DC motors They develop ungodly torque at stalled or near stalled speed so no additional reduction gearing is necessary Unfortunately you can t operate a series wound DC motor at stalled or near stalled speed too long because the current draw is immense and the motor will just burn to a crisp Getting to the starter and taking the correct safety precautions like disconnecting the battery are your responsibility The bolts that hold my starter in are in a fairly tight spot used a 1 4 drive breaker bar and a 13mm socket The bolts have plenty of thread engagement so be prepared to turn turn turn Take care when disconnecting the heavy wire lugs from the starter These studs and nuts are only copper and will not take much abuse Sometimes it is good to grip the heavy wire s terminal with pliers as a sort of back up wrench when trying to loosen the nut s With the starter out of the engine and in your hands 3 body bolts and one small torx head screw takes off the head of the starter Use a good torx screw driver Between the long torx screw that goes through the starter head and the two short ones that go from the backing plate into the solenoid broke the tip of my Sears Craftsman torx screw driver replaced those screws with two 4mm x 8mm and one 4mm x 35mm Allen headed cap screws Justifications for replacing the starter solenoid 1 The solenoid slug and or
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