Lucas starter motor/brushes

[Tim Comer]

I am trying to reassemble my Lucas starter motor but i am not sure how to get the armature past the brushes, i can not find anything in the manuals i have, can anyone advise please?

[mathias1]

there's a way to set the springs so it will pass. then you can use a screwdriver to let them spring in the correct spot.

[Tim Comer]

There’s obviously a way of doing this as brushes are a service part, but its eluding me at the moment, perhaps someone can elaborate?

[mathias1]

Tim,

Its hard to explain, but in this video you can see how to do it
https://youtu.be/PYdCp4IMDk8

[Tim Comer]

Thank you for your reply Mathias, the starter motor is different to the dynamo, the four brushes appear longer than those in your link and they are accessed by removing a cover, giving limited access, the brushes are soldered close fitting to the coils.

[Timeee]

Dear Tim

Not sure what your problem is here. You can lift the brush springs off the top of the brushes and rest them against the end of the brush holder frame, so that pressure is relieved on the brushes. With the brushes eased up their holders (not out of them) you can slide the commutator in. Then flip off the spring ends so that they bear onto the top of the brushes. Careful that the spring does not fly off its holder and ping into the wild blue yonder when you lift it off the brush.

Tim E

[mathias1]

Tim,

Like Timee says, you will have to use the same method as the dynamo. But you need to move springs when the brushes are just touching the anchor.

[Tim Comer]

Thanks chaps, I’ll have another go the weekend.

[mathias1]

Tim,

Did you gave it another try?

[Tim Comer]

After a lot of patience I managed to get the armature in , then whilst I was trying to reassemble the other end, it slid out, the air was blue, I will try again tomorrow, wish
me luck.

[Tim Comer]

After cleaning the brushes(good condition)and armature with electrical contact cleaner, I managed carefully to position the springs on the edge of the brush holders as suggested with the use of long nose pliers and screw driver, then reassembled and after bench testing I refitted to the Major and successfully started, I’m pleased to say. Thanks again Mathias and Tim for your advice.
Tim.

[Tim Comer]

Brush spring and brush images.