Rebuilding Starter
 

Two weeks ago I washed and waxed my FC and headed off to the gas station.
Jumped in after gassing up and no start.
Thought it might be the battery as I was only getting a click from the starter. Jumping the battery didnt help and I had to leave my baby sit overnight.
Read the post in here on the mystery starter
https://www.rx7club.com/2nd-generati...ystery-896013/
and jumped the cut off relay to no avail.

By odd luck got it to start by shorting a screwdriver between the battery and start post on the solenoid. Drove it home and it did the same thing (no start) so I took the starter out and took it apart.

Found the brushes to be worn down to the stops on the positive brushes.
Ordered a new set and opened the package to find the positive brushes aren't installed in the new brush assembly.

I was also wondering how to install the new assembly and maybe they weren't installed for a reason.

Anyone know how to reassemble the new brushes back on the rotor?

Attachment 610273

Attachment 610274

Does the backing plate have small holes where the brushes sit?
Usually when you put a new set of brushes in you can stick a toothpick in the holes and it will hold the brushes back enough to get the stator shaft in,then you release the toothpick and the brushes settle onto to the shaft.

Didn't see any holes on the old one or new.

I watched that a few days ago.
At 11:27 he has the brushes with wire attached (I suppose to the springs somehow) but the next shot the starter is back together with no explanation of how he pulled the wire out or sliding the brushes back on.

Thanks anyway.

What I did was this.
With a needlenose pliers I carefully pulled the springs back on top of the metal brush housing.
Attachment 610233

Then layed the assembly on the rotor and released the springs.
Attachment 610234

Then put the end cap and screws back on the starter.
Attachment 610235

I doubt this is the way it was supposed to be done but it worked.
Well, I think it worked, I can't find the one long bolt that holds the works together but I'll look around for that tomorrow and test it before it goes back in the car.

Thanks for the replies.

install the brush unit onto the commutator without the back cap. you can hold the brush outward and slip it over the commutator. once its in, line up the brush unit and the back cap together and install the screw and bolt.
and you beat me to it :P

LOL, I never would have guessed that to be right.

I thought about holding the brushes back with my fingers but it's a tight fit with new, long brushes and springs.
If the needle nose would have lost grip and the spring would fly off I would have never found it.
Also kept my fingers out of the way while gripping them. I was imagining a nice hole in my thumb a few times.

Wires outside the unit, install the cap, pull wires and button up.

i have put it back on with my hands, than again they were the old brushes :P

you won't get a brand new set of brushes on with just your finger holding them out of the way, a new brush set and holder is rather difficult to install and he did it one of a couple proper ways.