Cummins/Onan — Electric Starter Disassembly
Repair & overhaul · Starter motor
From a Cummins/Onan service manual — check it applies to your exact model before use.
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Procedure
- Remove all wires to starting unit. Tag each wire so it can be reconnected as originally.
- Remove solenoid (where applicable).
- Remove starter motor thru-bolts and divide starter into three main assemblies: front bracket, housing, rear bracket.
- Solenoid Starter Only: Remove armature from front bracket. Be careful not to miss small steel washer in end of armature shaft. Remove shift lever at same time armature is removed.
- Solenoid Starter Only: Remove ring after driving pinion stopper toward pinion gear using a cylindrical tool. Remove overrunning clutch and pinion stopper at same time.
- Gear Drive Starter Only: Pay particular attention to various parts and their positioning. If gears of pinion are damaged, replace entire pinion. Inspect screw shaft for rust and burrs.
- Remove brushes from brushholder and inspect them.
- Remove pole shoes if necessary by removing flathead machine screws which anchor them to frame.
Tools required
- Cylindrical tool for driving pinion stopper Amazon
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.