Cummins/Onan 4.0 BF-1R/9500 — Starter Disassembly
Repair & overhaul
For the Cummins/Onan 4.0 BF-1R/9500, from the Cummins/Onan service manual.
Browse Cummins/Onan generators & specs →
Before you start
- Do not immerse field coil, yoke, armature or solenoid in cleaning solvent
- Do not immerse overrunning clutch in cleaning solvent
Procedure
- Loosen nut attaching solenoid motor terminal to field coil connector lead; take off connector lead
- Loosen retaining screws and remove solenoid from front bracket (fiber washers, return spring, plunger come off)
- Unscrew through bolts and separate yoke with rear bracket from front bracket
- Remove armature from front bracket (shift lever, lever spring, spring holder come off)
- Remove insulated brush from brush holder to separate rear bracket from yoke
- To remove overrunning clutch, put metal cylinder over armature shaft end, tap to move stop ring, remove lock ring
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
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.