Cummins/Onan 4.0 BF-1R/9500 — Starter Reassembly
Repair & overhaul
For the Cummins/Onan 4.0 BF-1R/9500, from the Cummins/Onan service manual.
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Before you start
- Lubricate with very light grade oil; medium or heavy oil may cause faulty operation in cold weather
Procedure
- Lubricate armature shaft and splines with a very light grade oil
- Install overrunning clutch assembly, ring and stop ring on armature shaft
- Apply small amount of lubriplate on shift lever pivot pin and lever holders
- Install shift lever over clutch assembly with position indicated in Figure 56
- Place thrust washer on drive end of shaft; slide armature with lever into front bracket
- Place lever spring and spring holder into front bracket
- Position yoke to front bracket properly indexed
- Place thrust washer (steel) and washer (fiber) on commutator end of shaft
- Insert two brushes and springs in holders; secure brushes by iron wires
- Position rear bracket to yoke with rubber gasket; withdraw iron wires; fasten through bolts
- Install solenoid plunger over shift lever; install solenoid
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.