Atreidae
09-03-2011, 05:45 PM
Hey guys, First time poster here.
I used to write a few AV guides over at Just commodores and Ausrevs (many years ago)
Anyway, Ive had a KS touring pack manual for about 3 years and so far, its served me pretty well so I cant complain.
anyway, after coming across this community after changing my clutch (and then finding the relevant thread) I felt pretty stupid.
Anyway! To the point of the tread!
Ive just spent and entire day going around to different wreckers trying to find a starter motor to suit my KS.. First things first, I will point out, even though they look similar the Quad Cam starter motors do not fit on the twin cam motors, maybe with this mod, I'm not sure (post if you try it)!
Next thing, is the starter motors for the Manual and the Auto ARE DIFFERENT! they may look identical and most wreckers will tell you they aren't sure. but they are different.
Now its safe to assume that you have the old starter motor so you have the part needed to convert the Auto one into a Manual one.
I will warn you in advance, I was very irritated as I took these images, and they are of the auto one going back together, but the process is still the same, But I will apologise for the lack of quality
**********
*Disclaimer*
**********
I hate to put these in, but I've been burnt before.
If you read this information, and then do anything based on the information contained within, and you break something, injure yourself, blow up or are convicted of murder, I or Aussiemagna.com are not liable.
Begin guide.
-------------
If you look at this image, you can see the nose cones from the starter motors, the left one is the auto one and the right one is the manual one, as you can see.. Very similar, however this angle helps show the problem, as you can see the opening on the Right one is larger.
http://www.chibiko.net/ks-starter/IMG_1004.JPG_s.jpg
We need to take this part off our old (assumed dead) starter motor and fit it to the new one without breaking anything.
We also assume in this guide you already have the starter motor out.
Start by undoing the 2X 8mm Bolts on the main assembly.
http://www.chibiko.net/ks-starter/IMG_1021.JPG_s.jpg
DO NOT REMOVE the small metal cover (the metallic covered section) from the motor casing (Black section) otherwise you have to reset the brushes (not fun)
Undo the 12mm nut on the solenoid holding the tag to the actual motor itself
http://www.chibiko.net/ks-starter/IMG_1022.JPG_s.jpg
Remove the entire motor assembly, it should come away from the nose cone cleanly.
You might drop a ball bearing at this stage, keep it handy if you need to keep stripping, otherwise pop it back in the hole in the middle of the gearset.
http://www.chibiko.net/ks-starter/IMG_1012.JPG_s.jpg
Now, depending on the fault.. you can just do this on the other motor and swap the motor assemblies, my solenoid failed due to the motor failure, I also replaced the throw out gear as the teeth on mine were in much better condition. so if you wish, continue reading its not that hard (once you know how to pull these apart)
Now, you are going to need a P2 or P3 (not sure) phillips, ideally a socket-able type, if your screwdriver comes to a "point" of any description, its too small and will just round off the screws (trust me)
Remove the 2 Philips screws on the solenoid assembly. (notice the rounded screw, opps!)
http://www.chibiko.net/ks-starter/IMG_1019.JPG_s.jpg
Pull the solenoid off.. replace as required. if you need to replace the throw out gear read on.
you should see something like this, Remove the rubber insert and the small metal plate and the solenoid plunger (it just unhooks)
http://www.chibiko.net/ks-starter/IMG_1018.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1017.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1015.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1014.JPG_s.jpg
Remove the rubber seal from around the outside of the gearset (pictured here already removed. I was angry remember)
http://www.chibiko.net/ks-starter/IMG_1013.JPG_s.jpg
Remove the 3 planet gears from the orbiral gear set, (they just pull off) keep aside
http://www.chibiko.net/ks-starter/IMG_1011.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1010.JPG_s.jpg
Using your fingers, convince the throw out gear to come back through the assembly, be careful of the leaver and its orientation.
you should end up with this (notice I still have my leaver on, it just slides off if needed)
http://www.chibiko.net/ks-starter/IMG_1008.JPG_s.jpg
The empty nose cone (as you might notice, I'm doing this on the road.. very frustrated!)
the assembly is just the reverse of the dis-assembly, things to note, there are 2 tabs on the white plastic ring that line up in the nose cone, the 2 notches in the rubber line up with the screw holes and the 2 tabs on the motor assembly face towards the solenoid assembly, and make sure you line every thing up nicely.
Now, I also have a shot of the quad cam motor verses the twin cam here, note the solenoid is on the other side and there is some flashing, but from memory (sorry, I cant remember...) they use the same gearset, so the actual motors MIGHT be interchangeable.
TR-TS on the left, dunno what on the right.
http://www.chibiko.net/ks-starter/IMG_1006.JPG_s.jpg
Also, if you stuff up like I did and pull the brushes off.. dont try and "slip" it back in, I screwed my stator trying this. Pull the 2 philips heads out, the brushes will separate from the "lid", get them on the stator then pop the lid back on.
I hope someone finds this thread useful. and please! post if you try the Quad cam conversion, I know that TR-TS starters are getting hard to find.
I used to write a few AV guides over at Just commodores and Ausrevs (many years ago)
Anyway, Ive had a KS touring pack manual for about 3 years and so far, its served me pretty well so I cant complain.
anyway, after coming across this community after changing my clutch (and then finding the relevant thread) I felt pretty stupid.
Anyway! To the point of the tread!
Ive just spent and entire day going around to different wreckers trying to find a starter motor to suit my KS.. First things first, I will point out, even though they look similar the Quad Cam starter motors do not fit on the twin cam motors, maybe with this mod, I'm not sure (post if you try it)!
Next thing, is the starter motors for the Manual and the Auto ARE DIFFERENT! they may look identical and most wreckers will tell you they aren't sure. but they are different.
Now its safe to assume that you have the old starter motor so you have the part needed to convert the Auto one into a Manual one.
I will warn you in advance, I was very irritated as I took these images, and they are of the auto one going back together, but the process is still the same, But I will apologise for the lack of quality
**********
*Disclaimer*
**********
I hate to put these in, but I've been burnt before.
If you read this information, and then do anything based on the information contained within, and you break something, injure yourself, blow up or are convicted of murder, I or Aussiemagna.com are not liable.
Begin guide.
-------------
If you look at this image, you can see the nose cones from the starter motors, the left one is the auto one and the right one is the manual one, as you can see.. Very similar, however this angle helps show the problem, as you can see the opening on the Right one is larger.
http://www.chibiko.net/ks-starter/IMG_1004.JPG_s.jpg
We need to take this part off our old (assumed dead) starter motor and fit it to the new one without breaking anything.
We also assume in this guide you already have the starter motor out.
Start by undoing the 2X 8mm Bolts on the main assembly.
http://www.chibiko.net/ks-starter/IMG_1021.JPG_s.jpg
DO NOT REMOVE the small metal cover (the metallic covered section) from the motor casing (Black section) otherwise you have to reset the brushes (not fun)
Undo the 12mm nut on the solenoid holding the tag to the actual motor itself
http://www.chibiko.net/ks-starter/IMG_1022.JPG_s.jpg
Remove the entire motor assembly, it should come away from the nose cone cleanly.
You might drop a ball bearing at this stage, keep it handy if you need to keep stripping, otherwise pop it back in the hole in the middle of the gearset.
http://www.chibiko.net/ks-starter/IMG_1012.JPG_s.jpg
Now, depending on the fault.. you can just do this on the other motor and swap the motor assemblies, my solenoid failed due to the motor failure, I also replaced the throw out gear as the teeth on mine were in much better condition. so if you wish, continue reading its not that hard (once you know how to pull these apart)
Now, you are going to need a P2 or P3 (not sure) phillips, ideally a socket-able type, if your screwdriver comes to a "point" of any description, its too small and will just round off the screws (trust me)
Remove the 2 Philips screws on the solenoid assembly. (notice the rounded screw, opps!)
http://www.chibiko.net/ks-starter/IMG_1019.JPG_s.jpg
Pull the solenoid off.. replace as required. if you need to replace the throw out gear read on.
you should see something like this, Remove the rubber insert and the small metal plate and the solenoid plunger (it just unhooks)
http://www.chibiko.net/ks-starter/IMG_1018.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1017.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1015.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1014.JPG_s.jpg
Remove the rubber seal from around the outside of the gearset (pictured here already removed. I was angry remember)
http://www.chibiko.net/ks-starter/IMG_1013.JPG_s.jpg
Remove the 3 planet gears from the orbiral gear set, (they just pull off) keep aside
http://www.chibiko.net/ks-starter/IMG_1011.JPG_s.jpg
http://www.chibiko.net/ks-starter/IMG_1010.JPG_s.jpg
Using your fingers, convince the throw out gear to come back through the assembly, be careful of the leaver and its orientation.
you should end up with this (notice I still have my leaver on, it just slides off if needed)
http://www.chibiko.net/ks-starter/IMG_1008.JPG_s.jpg
The empty nose cone (as you might notice, I'm doing this on the road.. very frustrated!)
the assembly is just the reverse of the dis-assembly, things to note, there are 2 tabs on the white plastic ring that line up in the nose cone, the 2 notches in the rubber line up with the screw holes and the 2 tabs on the motor assembly face towards the solenoid assembly, and make sure you line every thing up nicely.
Now, I also have a shot of the quad cam motor verses the twin cam here, note the solenoid is on the other side and there is some flashing, but from memory (sorry, I cant remember...) they use the same gearset, so the actual motors MIGHT be interchangeable.
TR-TS on the left, dunno what on the right.
http://www.chibiko.net/ks-starter/IMG_1006.JPG_s.jpg
Also, if you stuff up like I did and pull the brushes off.. dont try and "slip" it back in, I screwed my stator trying this. Pull the 2 philips heads out, the brushes will separate from the "lid", get them on the stator then pop the lid back on.
I hope someone finds this thread useful. and please! post if you try the Quad cam conversion, I know that TR-TS starters are getting hard to find.