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Johnson 1980 55HP Starter Motor Cleaning/Reassembly

jasondainter

jasondainter

Regular Contributor
Hi Folks.

I was doing some overall servicing on my Johnson 55hp 1980 (55EL80C) to the lower unit (reverse gear/clutch dog needed replacing) so whilst I had the starter motor off (was much easier to get the lower unit off with that removed) I figured I would take it apart and see how it looked inside.

Do people think this is dirty enough to warrant cleaning or do the cable connectors normally look like this below? The motor actually starts fine (sometimes takes a few attempts but I normally put them down to 'personality!'), so I dont have any real reason to clean but ti me these look pretty filthy. Thoughts? I as considering trying my best to clean them up with a wire brush / some brake cleaner etc, thoughts on that?

Does anyone have any tips on how to hold the springs in place when I reassemble the unit? Seems like a fiddly procedure any tricks involved there?

Finally, does anyone know how to get that told nut off so I can give all the top parts a good clean. I'm wondering how to best grip the thing as it pretty wedged on.

Thanks ahead.

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I get new brushes from local starter / alternator shop at $6.00 a set.-----You need new brushes.----Take an ohm reading from commutator to the shaft.-----Almost looks like it might have been hot to me.------Should read infinity on a digital meter.-----Assembly?----You can buy a special tool.-----Or use a putty knife with a slot to hold the brushes in place.---Then drop the armature in place.----I use a piece of sheet metal with a slot.----Works everytime !!
 
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Thanks a lot - I just bought https://www.ebay.co.uk/itm/323074327818 so ill replace all the brushes as you suggest.

Ill try an ohm reading. Bit of a noob at this, where abouts do you mean when you say the communicator / shaft?

Sheet metal/putty knife trick sounds perfect Ill give that a try.

Any ideas on how to remove that top nut? Its quite wedged on and I dont want to damage something when taking it off (was hoping to get it off so I could clean the top half).

I presume when re-assembling i'll need to put some marine grease on the top of the armature (the part the drive assembly slides up and down). Anything else that needs thinking about?

Really cant wait for my service manual to arrive!
 
We all use an air impact tool to remove the Bendix nut. Otherwise grab the gear with a pair of Channelock pliers. Don't grease the Bendix. But a couple drops of oil is ok. The communtator is the slotted copper end on the armature.
 
By "top nut" I assume you are referring to the nut on the very end of the shaft.
Usually, people put a strap wrench around the armature to get a good grip.
Or, use a small electric impact wrench on the nut.
 
Thank you very much this is super helpful!

Yes exactly the nut at the top of the shaft.

I have an air impact drill so I'll give that a go. I think I read on another thread here you can grip (with a spanner I guess) that hexagonal part seen in the picture then airgun off the nut. Fingers crossed that will work I'll give it a try tomorrow!

Good tip on the oil thanks. Any reason not to grease that out of curiosity? Is it because the grease can dry up over time? RE oil just to be sure would marine gear oil work ok in that case?
 
That funny-----Can you guys not see the hex on the bottom of the drive ???----It is provided to help take nut off the shaft !!
 
Came off fine in the end easier than I expected just gripping the hex with a spanner and socket on the top. Thanks for all the help!
 
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