Self start motors fail once in a while and one of the common failure is worn out carbon brushes which conduct the electric power from battery to the motor armature coil. On frequent usage those carbon brushes tend to wear, resulting in improper / insufficient contact between the brush and the armature coil.


People charge around 350~600 INR to service the 2 wheeler starter motor (replacing the carbon brushes) and some greedy & lazy mechanics replace the worn out starter motor with brand new one costing between 1000~2000 INR. Follow the below easy steps, you could get the work done with less than 150 INR and 15~20 mins time.


Below is the reference of Bajaj Pulsar 150 UG3 (same procedure is applicable for most of the other brands / bikes except for the one which comes with soldered terminals)


Tools Required:
- 8 mm Spanner
- 10 mm Spanner
- Phillips Screw driver
- Cir-clip removal pliers (External hole type) - Optional
- Emery paper
- Grease
- Brush Kit (Bike specific)


Procedure
- Remove the starter motor from the bike
- Clean the outer surface for dust / oil spill
- Unscrew these 2 long bolts with 8 mm spanner and pull the bottom cup to dismantle the starter assemble (Gently tap the motor shaft for easy removal)




- These are the worn out carbon brushes and the retaining springs




- Remove the housing / base plate with Phillips head screw driver
- Remove the -ve terminal brush with Phillips head screw driver and the +ve terminal brush with 10 mm spanner




- Clean the Armature contact area with emery paper (take care not to shave-off the base metal, clean only the dirt deposition) This snap was taken after cleaning




- Apply grease over the marked area




- Open the Brush replacement kit




Kit comes with
* Carbon Brushes
* Housing / Back plate
* Retaining Springs
* All necessary fasteners




- Follow the reverse procedure to assemble the starter motor.
- Use Cir-clip removal plier to hold the brush in position (against the spring load) while inserting the armature (I could not take the snap of this step)








- Confirm the free rotation of motor shaft before fixing back to the vehicle.


Total Cost : 110 INR
Time Consumed : 15 mins


Fitted back the starter motor on the bike and it works like a charm


Disclaimer:
I'm not good at electrical parts / systems. If there is any correction in the above mentioned procedure or the terms used, kindly excuse me and feel free to correct the same.