Starter_Boot_Replacement_Work_Instruction__5.7.3.pdf

SOLENOID BOOT REPLACEMENT

Tools Crows feet, 10 mm, 3/8 inch drive Extension, 12 inch, 3/8 inch drive Ratchet, 3/8 inch drive Socket, 12 point, 10 mm, 3/8 inch drive Socket, 13 mm, 3/8 inch drive Socket, 14 mm, 3/8 inch drive Socket, deep well, 14 mm, 3/8 inch drive Socket, deep well, 17 mm, 3/8 inch drive Socket, deep well, 3/4 inch, 3/8 inch drive Wrench, 12 point, 10 mm

Materials Marker, paint Rag

4. Remove ground wire from back of starter using 3/8 inch drive ratchet and 3/8 inch drive 3/4 inch deep well socket.

5. Remove power cable from back of starter solenoid using 3/8 inch drive ratchet and 3/8 inch drive 14 mm deep well socket.

6. Remove convoluted tubing from wire and disconnect engine wiring harness from solenoid (Figure 2).

7. Remove clamp from power pack using 3/8 inch drive ratchet and 3/8 inch drive 13 mm socket.

Figure 1. Starter Wiring Removal.

Ground Wire

Power Cable

Convoluted Tubing

Clamp

SOLENOID BOOT REPLACEMENT – Continued

Figure 2. Engine Wiring Harness Disconnection.

8. Remove three bolts securing starter to power pack using 10 mm 12 point wrench, 3/8 inch drive ratchet, and 3/8 inch drive 10 mm 12 point socket (Figure 3).

Figure 3. Starter Removal.

Disconnect Wires Here

Attach Bolts

9. Remove terminal lug from solenoid using 3/8 inch drive ratchet and 3/8 inch drive 17 mm deep well socket (Figure 4).

Figure 4. Terminal Lug Removal.

10. Mark solenoid and starter mating surfaces with a paint marker so proper orientation will be retained (Figure 5).

11. Remove two bolts from solenoid using 3/8 inch drive ratchet, 3/8 inch drive 12 inch extension, and 3/8 inch drive 10 mm socket (Figure 5). Carefully remove solenoid, the starter drive gear may need to be rotated to unhook the solenoid shaft from the fork.

Terminal Lug

Figure 5. Solenoid Removal.

12. Pull the old rubber boot off the front of the solenoid (Figure 6).

Figure 6. Old Boot Removal.

Make Mark Here

10 mm Bolts

13. Clean the solenoid shaft using rag and install new boot (Table 1, Item 1) onto solenoid. Ensure the lip on the inside of the boot tip seats in the grove on the solenoid shaft (Figure 7).

Figure 7. New Boot Installation.

14. Ensure the housing flange and the fork are clean before installing the solenoid. Ensure alignment marks are lined up and fit the solenoid back into the housing, ensuring the shaft has engaged the fork (Figure 8).

Figure 8. Fork Engagement.

15. Line up alignment marks and install two mounting screws (Item 2) and two washers (Item 3) using 3/8 inch drive ratchet, 3/8 inch drive 12 inch extension, and 3/8 inch drive 10 mm socket (Figure 9). Torque bolts to 96 in-lbs using 3/8 inch torque wrench and 3/8 inch drive 10 mm socket. Torque stripe bolts.

Figure 9. Solenoid Installation.

Table 1. Parts List – Solenoid Installation.

ITEM NO NOMENCLATURE PART NO NIIN QTY

1 Solenoid Boot R0167697 01-650-9442 1

2 Bolt Reclaimed 2

3 Washer Reclaimed 2

16. Install terminal lug on solenoid using 3/8 inch drive ratchet and 3/8 inch drive 17 mm deep well socket. Make sure terminal lug does not touch side of starter (Figure 10). Torque to 35 in-lbs. using 3/8 inch drive torque wrench and 3/8 inch drive 17 mm deep well socket. Torque stripe nut.

Figure 10. Terminal Lug Installation.

17. Line starter up to opening and install starter with three bolts (Table 2, Item 1) using 10 mm 12 point wrench, 3/8 inch drive ratchet, and 3/8 inch drive 10 mm 12 point socket and 3/8 inch drive 10 mm splined crows foot.

Torque bolts to 32 ft-lbs using 3/8 in drive torque wrench and 3/8 inch drive 10 mm 12 point socket and 3/8 inch drive 10 mm splined crows foot (Figure 11).

Figure 11. Starter Installation.

Terminal Lug

Table 2. Parts List – Solenoid Installation.

ITEM NO NOMENCLATURE PART NO NIIN QTY

1 Bolt 3968470 01-547-2501 3

18. Install ground wire on back of starter using 3/8 inch drive ratchet and 3/8 inch drive 3/4 inch deep well socket (Figure 12). Torque nut to 35 in-lbs using 3/8 inch drive torque wrench and 3/8 inch drive 3/4 inch deep well socket. Torque stripe nut.

19. Install power cable on back of starter solenoid using 3/8 inch drive ratchet and 3/8 inch drive 14 mm deep well socket (Figure 12). Torque nut to 35 in-lbs using 3/8 inch drive torque wrench ratchet and 3/8 inch drive 14 mm deep well socket. Torque stripe nut.

20. Connect engine wiring harness to solenoid wire and install convoluted tubing (Figure 2).

21. Install clamp from power pack using 3/8 inch drive ratchet and 3/8 inch drive 13 mm socket. Torque clamp to 35 in-lbs using 3/8 inch drive torque wrench and 3/8 inch drive 13 mm socket. Torque stripe bolt.

Figure 12. Starter Electrical Connections.

END OF TASK

Ground Wire

Power Wire

Clamp

Convoluted Tubing