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Can Starter Motor Terminal Be Serviced?

Discussion in 'The Garage' started by YL82, Jan 30, 2013.

  1. YL82

    YL82 Perpetual Restorationist

    I am able to make a decent connection with what little thread I have left to work with using the 10mm nut to secure the starter motor cable, but its a tenuous situation.

    Broke about 3/16" of threads off while tightening (perhaps overly so) the nut to make sure the cable was secured. Snap! :banghead:

    I serviced the starter (new brushes, sanded commutator, cleaned armature, etc.) and hate to go back inside just to look whether terminal can be replaced.

    Anyone know whether terminal can be replaced from the inside of the housing with a new bolt? Other ideas?


    Attached Files:

    gggGary likes this.
  2. pamcopete

    pamcopete Ride.Enjoy.Life is Simple

    I think everybody is waiting so you can tell us! :D
  3. YL82

    YL82 Perpetual Restorationist

    Oh, I see how it is! :)

    Sure, I'll check it out.

    I don't know the full length that needs to protrude out of the starter if I am able to put in another bolt. Sure don't want a new one to protrude too much since that terminal is in harms way and is easy to knock off (and overtorque as I learned).

    Attached Files:

    Last edited: Feb 8, 2013
  4. YL82

    YL82 Perpetual Restorationist

    After taking a closer look, I don't consider the terminal to be servicable - at least I'm not going to mess with it from the inside (see images).

    I plan to try either a coupling nut and short section of all-thread or (in all likelihood) a Male to Female Threaded Hex Standoff (from McMaster Carr). Never heard of a standoff before a couple days ago, but I'm hopeful that will work for me.

    Attached Files:

  5. retiredgentleman

    retiredgentleman XS650 Guru Top Contributor

    Looks like you may be able to repair the terminal.

    However, if it does not work for you, you can just buy another starter motor. Many of the young lads like to remove the starter motor, and just do the kick thing. There should be lots of them for sale.
    gggGary likes this.
  6. Downeaster

    Downeaster Everything in XS Top Contributor

    You are correct, that terminal is not serviceable by the average home mechanic.

    It is silver-soldered to the field windings in the motor case.

    A good starter/generator shop would be able to fix it tho.

    Edit: As long as you pay attention to the insulation, there's no reason the hex standoff won't work.
    gggGary likes this.
  7. YL82

    YL82 Perpetual Restorationist

    Considering that I'm a below-average home mechanic, that definetly rules me out! :D

    I had assumed (incorrectly) that it would be hard to locate a replacement starter motor. Then again, I haven't been looking for one. I'm damn near 50 yrs. old so I think I'll keep using a starter motor.

    I'll report back on how the standoff works out. May be a while since I'm doing my first engine rebuild. I've been meaning to start a new thread - still in disassembly stage.
    gggGary likes this.
  8. Downeaster

    Downeaster Everything in XS Top Contributor

    I'm 62 and I don't think that even puts me in the Top Ten for Chronologically Challenged XS Riders. :laugh::bike:
    lakeview, TwoManyXS1Bs and gggGary like this.
  9. Shipper

    Shipper XS650 Addict

    70 and still kicking it over w/o any problems. C'mon Man!!
    TwoManyXS1Bs and gggGary like this.
  10. kevski

    kevski XS650 Addict

    kent uk
    Carefully file the threads off, and re-cut with a 5mm die then use slightly larger outside diameter 5mm washers, job done.
    Bushyeyed1 likes this.
  11. kshansen

    kshansen XS650 Junkie Top Contributor

    I was going to comment on this thread saying I had a starter I could rob parts from to fix this one, I would sell cheap to help fix this one then noticed it was a never closed thread from back in 2013!

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