Cummins/Onan 3.6MKY / 4MKY — Starter Reassembly
Repair & overhaul · Electric starter
For the Cummins/Onan 3.6MKY / 4MKY, from the Cummins/Onan service manual.
Applies to: Cummins/Onan 3.6MKY, Cummins/Onan 4MKY
Before you start
- Do not immerse bearings in cleaning fluid
- Avoid getting oil on brushes or commutator
Procedure
- Wipe dirt and oil from starter components; blow off dust with filtered low-pressure compressed air.
- Push negative brush terminals over the through-bolt holes on the brush endcap.
- Insert positive brush stud into hole and torque to 25-30 lb-in. (2.83-3.39 N-m).
- Insert brush springs into holders and brushes into holders in endcap; all brush wires facing up.
- Place washer on commutator end of shaft; put armature into brush endcap.
- Ensure brush wires clear of commutator and uninsulated wires do not touch housing.
- Place magnetic housing over armature.
- Place spring washer and flat washer on shaft.
- Place mounting bracket on motor with through-bolt lead-ins to inside.
- Insert through-bolts and torque to 35-45 lb-in. (3.96-5.09 N-m).
- Apply light coat of GE Versilube 322-L to helix, gear and unchamfered end; place clutch and helix on shaft.
- Assemble return spring components as required.
- Mount starter on endbell and tighten mounting bolts to 30-33 lb-ft (41-45 N-m).
- Install engine bracket, muffler bracket hardware and rear starter mounting nut.
- Connect positive (+) cable; mount housing; reconnect battery negative terminal last.
Specs & values
- Positive brush stud torque 25-30 Amazon eBay FridayParts $173.00 lb-in (2.83-3.39 N-m)
- Through-bolts torque 35-45 Amazon lb-in (3.96-5.09 N-m)
- Starter mounting bolts 30-33 lb-ft (41-45 N-m)
Source: Cummins/Onan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.