Thread: starte brushes

hey has any one replaced starter brushes on the old Honda 300s them selves? is it easy to do??

Yes, On the mag cover(left hand side of engine) there is another little cover which is held on by 5 bolts(8mm heads), Remove this making sure you take note of where the gears/shaft shim goes.(there only a couple,not as scary as it sounds).Now put it to one side and remove the starter motor.

Remove the power lead that's on top of the starter motor,u'll need 2 10mm spanners-1 to hold bottom nut and the other to undo the top nut. Then remove the 2 bolts at the back holding the starter motor to the engine,1 of these holds the earth strap in place....grab a screw driver and lever the starter back and out of its home.

Now it has 2 locator marks to make sure its all lined up,if you cant find them just scribe a line at each end where it separates, remove the 2 bolts holding it all together(7mm heads and long) pull the end caps off,be careful and take not of what shims go where(it matters).
1 end cap will hold the brushes and the other has a bearing in it, clean with brake clean or just blow out,replace brushes in the reverse of what you removed them.
Remove the armature from from the magnets and clean up the surface where the brushes run with wet/dry sand paper or any sand paper it doesn't matter.

Now put it all back together the same way you disassembled it,grab some jumper leads and put the earth on the body of the motor and power to the pole that sticks out of it and should zoom into life,if it don't you've put it back together wrong.

Bolt it back onto engine chuck some gasket goo around that cover you took off 1st,line all the gears up-bolt it on and you should be away.
If you get stuck and forget where something goes use this Fast shipping. Up to 40% off Honda, Yamaha, Kawasaki, Suzuki and Polaris OEM motorcycle parts and accessories. Deep reseller discounts. its a parts list site and has diagrams exactly like the bike shops have,find trx300 and follow your nose.

awesome thanks for that. I can wait for my boss to do it in another 5 weeks but I wouldn't mind doing it myself. ill try it this weekend or monday

There are a few manuals here

Service Manual Downloads - All years - Honda ATV Forum

Originally Posted by Frosty

Yes, On the mag cover(left hand side of engine) there is another little cover which is held on by 5 bolts(8mm heads), Remove this making sure you take note of where the gears/shaft shim goes.(there only a couple,not as scary as it sounds).Now put it to one side and remove the starter motor.

Remove the power lead that's on top of the starter motor,u'll need 2 10mm spanners-1 to hold bottom nut and the other to undo the top nut. Then remove the 2 bolts at the back holding the starter motor to the engine,1 of these holds the earth strap in place....grab a screw driver and lever the starter back and out of its home.

Now it has 2 locator marks to make sure its all lined up,if you cant find them just scribe a line at each end where it separates, remove the 2 bolts holding it all together(7mm heads and long) pull the end caps off,be careful and take not of what shims go where(it matters).
1 end cap will hold the brushes and the other has a bearing in it, clean with brake clean or just blow out,replace brushes in the reverse of what you removed them.
Remove the armature from from the magnets and clean up the surface where the brushes run with wet/dry sand paper or any sand paper it doesn't matter.

Now put it all back together the same way you disassembled it,grab some jumper leads and put the earth on the body of the motor and power to the pole that sticks out of it and should zoom into life,if it don't you've put it back together wrong.

Bolt it back onto engine chuck some gasket goo around that cover you took off 1st,line all the gears up-bolt it on and you should be away.
If you get stuck and forget where something goes use this Fast shipping. Up to 40% off Honda, Yamaha, Kawasaki, Suzuki and Polaris OEM motorcycle parts and accessories. Deep reseller discounts. its a parts list site and has diagrams exactly like the bike shops have,find trx300 and follow your nose.

Good write up Also when assembling put a bit of grease on the armature shaft (at the brush end) It will stop horrible noises happening, And when fitting the outer cover back on, Take note of the 5 bolt's, 1 is shorter and goes into bottom hole, If not oil will leak out no matter how much poo is on there

just taken the starter of now about to take it apart. put the 5 screws back so I didn't misplace them. ill let you know how I get on. cheers for the posts

qauds all fixed now. thanks heaps guys used both advise to do it. cheers

Sweet