Starter Motor Lead

[philward]

Help from the sparkies please! The starter motor that I've got for the CR project has had the lead cut off and I need to replace the lead completely to accommodate the re-positioning of the smaller battery under the seat. My last rebuild on my k2 had a copper stud and nut on the motor and an eye on the lead but the few starter motors I have all have the lead directly soldered into the motor. So, how do I connect a new lead as I am a bit apprehensive about applying heat via a gas torch (a soldering iron won't generate enough heat I'm sure?) as this may damage the covering on the windings where the cable enters the body on the inside. I was thinking of whether I could drill and tap where the cable enters the starter motor body (as per my K2 type) and insert a m6 copper stud.
Any advice welcome please.
Phil

[philward]

some pics

[hairygit]

Yes a stud would work, but NO part of it can be allowed to contact the body of the starter motor, it would need nylon "top hat" type insulating bushes to ensure effective insulation, even with such bushes there would be a danger of them melting if the started motor was operated for more than 30 seconds under load and shorting itself out.

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[philward]

Hairy, I think it already has the plastic top hat on now - I'd just have to ensure I didn't damage it when drilling. Would a copper stud be necessary or could I get away with steel? On the CSML schematics, I can't find which model uses the studded starter motor body - anyone know?

[hairygit]

You could use steel, although stainless would be better from a long term corrosion view.

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[philward]

Good, I've loads of m6 studding - cheers.

[philward]

I've now removed the old brittle and cut starter lead then drilled and tapped M6 plus fitted copper stud. Before re-fitting I was looking to fit a new seal to the splined shaft and the O ring that seals the motor/crankcase. The seal is not listed separately and the O ring is an odd size (24.4x3.1mm). CMSL have the seal in stock but expensive plus postage - DS is out of stock.

How have other members dealt with the same issue? Should I just put it back with the old seals fitted (to be honest, that's what I did with my last rebuild)

[Trigger]

Are you on about part number 91215-300-03 ? If so, I am awaiting a trade pack of those.

[philward]

Hi Graham - the CMSL site lists it as 91309425003 (supersedes 91309300000)?

[Trigger]

Hi Graham - the CMSL site lists it as 91309425003 (supersedes 91309300000)?

Yes, I should have in stock by the end of the week, and not a fiver each 
I think I have replaced the other spline seal but, I am sure I just measured it up and ordered the same size.

[philward]

Cheers Graham - let me know when you have them in - and how much they are! Although I donate to the forum when you send me something, its still costing you!

[Trigger]

Cheers Graham - let me know when you have them in - and how much they are! Although I donate to the forum when you send me something, its still costing you!

99p  Your package should be with you tomorrow and it saves me donating 

[philward]

Never thought about it that way! Cheers Graham