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 - 0.0118", adjust with shims if necessary.

Fig 1: BOSCH STARTER (TYPICAL)
Courtesy of NOT AVAILABLE
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

Bosch⁽¹⁾ Part Number & (Type Number)

No Load Test

Lock Test

Amps

RPM

Amps

Volts

Torque

0001 155 -

(DD 12V 0.5PS)

20-40

6500-8500

260-340

9.0

6.4 ft. lbs.

230-310

8.0

5.6 ft. lbs.

0001 157 -

(DF 12V 0.5PS)

20-40

6500-8500

320-400

9.0

6.7 ft. lbs.

280-360

8.0

5.9 ft. lbs.

0001 207 -

(EF6V 0.5PS)

50-70

5500-7500

300-380

2.5

4.7 ft. lbs.

230-320

2.0

3.6 ft. lbs.

0001 208 -

(EF 12V0.8PS)

35-55

6000-8000

320-410

8.5

9.0 ft. lbs.

280-370

7.5

7.9 ft. lbs.

0001 211 0 -

(EF 12V 0.7PS)

30-50

6000-9000

300-390

9.0

8.7 ft. lbs.

260-350

8.0

7.2 ft. lbs.

0001 211 9 -

(EF 12V 0.7PS)

30-50

6500-9500

320-410

8.5

8.3 ft. lbs.

270-360

7.5

7.2 ft. lbs.

0001 212 -

(EB 12V0.8PS)

35-55

6000-8000

320-410

8.5

9.0 ft. lbs.

280-370

7.5

7.9 ft. lbs.

0001 310 -

(GF 6V 0.6PS)

35-65

4500-6500

290-370

2.5

5.1 ft. lbs.

220-300

2.0

4.0 ft. lbs.

0001 311 -

(GF 12V IPS)

30-50

5500-7500

350-450

8.5

13.0 ft. lbs.

310-400

7.5

11.6 ft. lbs.

0001 312 1 -

(GB 12V 1.5PS)

55-85

8500-10500

.....

13.7 ft. lbs.⁽²⁾

.....

11.6 ft. lbs. ⁽²⁾

0001 313 -

(GF 12V1.4PS)

50-80

8300-10300

.....

12.3 ft. lbs. ⁽²⁾

.....

10.7 ft. lbs. ⁽²⁾

0001 314 -

(GF 12V1.4PS)

50-80

7300-9300

.....

16.6 ft. lbs. ⁽²⁾

.....

13.7 ft. lbs. ⁽²⁾

0001 354 -

(JD 12V 1.8PS)

60-90

5000-7000

740-680

8.5

26.8 ft. lbs. ⁽²⁾

620-780

7.5

23.9 ft. lbs. ⁽²⁾

0001 356 -

(JB12V1.8PS)

60-90

5000-7000

720-850

8.0

29.6 ft. lbs. ⁽²⁾

620-750

7.0

26.0 ft. lbs.⁽²⁾

0001 362 -

(JF 12V2.5PS)

65-95

6500-8500

1100-1300

7.0

32.5 ft. lbs. ⁽²⁾

900-1100

6.0

26.8 ft. lbs. ⁽²⁾

⁽¹⁾	All starters of a particular part number group (i.e. 0001 211 - - - or 0001 211 9 - -) can be tested according to specifications following that group.

⁽²⁾	With 12 volt, 143 amp batteries connected in parallel.