Starters - BOSCH: Overhaul: Reassembly

NOTE: When reassembling, use all new gaskets, and when reassembly complete, paint all main joints on starter (including solenoid) with gum-lac, or an equivalent.

Clamp armature in a suitable holding fixture, line up armature brake unit and intermediate bearing. The bent ends of the spring plate washer unit must engage into holes of cupped washer of intermediate bearing.
Push drive over armature shaft, then push spring ring into groove (using suitable tool); use conical piece to force ring over after adjusting it with hex bolts, so that tube pushes spring ring straight into groove. Install castle nut and adjust with cotter pin.
Insert yoke lever, slipping drive end assembly over drive, being sure guide pins on fork are between guiding discs and that fork is in center of casting throat. Replace rubber seal to joint of drive end housing (on starters with intermediate bearing only).
Install intermediate bearing to drive end assembly and install through bolts in the reverse manner of their removal. Be certain intermediate bearing is properly seated to drive end assembly. Check armature brake spring ends to ensure proper positioning.
Insert armature, with drive end assembly into housing, do not damage field coils. Install washers on armature shaft as they were marked at disassembly, replace commutator end assembly. Check play of armature, this should not exceed 0.0029 - 0.01 18", adjust with shims if necessary.
Hook in joint fork of solenoid, pushing back engagement fork. Be certain rubber seal is installed between solenoid and drive end and copper washer on bearing bolt. Attach solenoid and field coil terminal to solenoid.
Connect field coil terminal to brush box and install brushes, making sure leads of brushes do not interfere with cover. Fasten dust cover, being certain to install gasket, bend tongues of lock washers.

STARTER PERFORMANCE SPECIFICATIONS

Model	No Load Test		Lock Test
Model	Amps.	RPM	Amps.	Volts	Torque
208 XXX	35-55	6000-8000	320-410	8.5	9 ft. lbs.
211 XXX	30-50	6000-9000	300-390	9.0	8.7 ft. lbs.
211 9XX	30-50	6500-9500	320-410	8.5	8.3 ft. lbs.
212 XXX	35-55	6000-8000	320-410	8.5	9 ft. lbs.
311 XXX	30-50	5500-7500	350-450	8.5	13 ft. lbs.
312 1XX	55-85	8500-10500	650-730	6.0	13.7 ft. lbs.
313 XXX	50-80	8300-10300	520-610	6.5	12.3 ft. lbs.
362 XXX	65-95	6500-8500	1100-1300	7.0	32.5 ft. lbs.