Cummins/Onan — Starter Disassembly (Solenoid Shift)
Repair & overhaul
From a Cummins/Onan service manual — check it applies to your exact model before use.
Applies to: Cummins/Onan MCCK
Before you start
- Starter motors are not designed for continuous operation. Do not operate more than 30 seconds per ON cycle. Do not operate starter more than 10 seconds in a stall condition.
Procedure
- Remove all wires to the starting unit. Tag each wire for reconnection.
- Remove the solenoid (where applicable).
- Remove the starter motor thru-bolts and divide starter into three main assemblies: front bracket, housing, and rear bracket.
- Solenoid starter only: remove armature from front bracket, being careful not to miss the small steel washer in the end of the armature shaft. Remove shift lever.
- Solenoid starter only: remove ring after driving pinion stopper toward pinion gear using a cylindrical tool. Remove overrunning clutch and pinion stopper.
- Gear drive starter only: note positioning of parts on armature shaft. If pinion gears 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.
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.
Full service-parts list: Cummins/Onan MCCK →
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.