Nissan/Datsun 200SX/510/610/710/810/Maxima 1973-1984 Repair Guide

Starter

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Datsun/Nissan began using a reduction gear starter in 1978 on the 810 and in the Canadian versions of the 510 and 200SX. They were also available as an option on the U.S. 510 and 200SX. The differences between the gear reduction and conventional starters are: the gear reduction starter has a set of ratio reduction gears while the conventional starter does not; the brushes on the gear reduction starter are located on a plate behind the starter drive housing, while the conventional starter's brushes are located in its rear cover. The extra gears on the gear reduction starter make the starter pinion gear turn at about half the speed of the starter, giving the starter twice the turning power of a conventional starter.

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Disconnect the starter wiring at the starter, taking note of the positions for correct installation.
  4.  
  5. Remove the bolts attaching the starter to the engine and remove the starter from the vehicle.
  6.  
  7. Install the starter to the engine.
  8.  
  9. Tighten the attaching bolts. Be careful not overtighten the mounting bolts as this will crack the nose of the starter case.
  10.  
  11. Install the starter wiring in the correct location.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine a few times to make sure of proper operation.
  16.  

SOLENOID REPLACEMENT



The starter solenoid is also know as the magnetic switch assembly.

  1. Remove the starter from the engine as outlined above.
  2.  
  3. Place the starter in a vise or equivalent to hold the starter in place while you are working on the solenoid. DO NOT tighten the vise to tight around the case of the starter. The case will crack if you tighten the vise to much.
  4.  
  5. Loosen the locknut and remove the connection from the starter motor going to the M terminal of the solenoid or bottom terminal of the solenoid.
  6.  
  7. Remove the securing screws and remove the solenoid.
  8.  
  9. Install the solenoid to the starter and tighten the securing screws.
  10.  
  11. Install the connection and locknut at bottom terminal of the starter.
  12.  

OVERHAUL



Brush Replacement
NON-REDUCTION GEAR TYPE


Click image to see an enlarged view

Fig. Fig. 1 To remove the starter, disconnect the lead wires, then unbolt the unit from the engine



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Fig. Fig. 2 Pull the starter away from the engine, wiggling it slightly if necessary, to disengage the gears



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Fig. Fig. 3 Exploded view of a non-reduction gear starter

  1. With the starter out of the vehicle, remove the bolts holding the solenoid to the top of the starter and remove the solenoid.
  2.  
  3. To remove the brushes, remove the 2 through-bolts, the 2 rear cover attaching screws (some models) and the rear cover.
  4.  

Remove the dust cover, E-ring and thrust washers from the armature shaft before the rear cover.

  1. Using a wire hook, lift the brush springs to separate the brushes from the commutator.
  2.  
  3. Install the brushes in the reverse order of removal and reassemble the rear cover to the starter.
  4.  

REDUCTION GEAR TYPE


Click image to see an enlarged view

Fig. Fig. 4 Exploded view of a reduction gear starter



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Fig. Fig. 5 Exploded view of a reduction gear starter-LD28 diesel engine

  1. Remove the starter, then the solenoid or magnetic switch.
  2.  
  3. Remove the dust cover, E-ring and thrust washers.
  4.  
  5. Remove the starter through-bolts and brush holder setscrews.
  6.  
  7. Remove the rear cover. The rear cover can be pried off with a screwdriver, be careful not to damage the O-ring or gasket if equipped.
  8.  
  9. Remove the starter housing, armature and brush holder from the center housing. They can be removed as an assembly.
  10.  
  11. Using a wire hook on the spring, lift the spring then remove the positive side brush from its holder. The positive brush is insulated from the brush holder and its lead wire is connected to the field coil.
  12.  
  13. Using a wire hook on the spring, lift the spring and remove the negative brush from the holder.
  14.  
  15. Replace all the brushes in the starter assembly.
  16.  
  17. Insert the new brushes in the brush holder.
  18.  
  19. Install the starter housing, armature and brush holder to the center housing.
  20.  
  21. Install the brush holder setscrews, rear cover and starter through-bolts.
  22.  
  23. Install the thrust washers, E-ring and dust cover.
  24.  
  25. Install the solenoid or magnetic switch.
  26.  

Starter Drive Replacement
NON-REDUCTION GEAR TYPE


Click image to see an enlarged view

Fig. Fig. 6 Remove the pinion stopper as shown

  1. With the starter motor removed from the vehicle, remove the solenoid from the starter.
  2.  
  3. Remove the 2 through-bolts at the rear cover but do not disassemble the entire starter. Mark the front gear cover with relationship to the yoke housing.
  4.  
  5. Separate the front gear case from the yoke housing, then the shift lever from the armature, without removing the armature from starter assembly.
  6.  
  7. Push the pinion stopper toward the rear cover, then remove the pinion stopper clip and the pinion stopper.
  8.  
  9. Slide the starter drive from the armature shaft.
  10.  
  11. Install the starter drive on the armature shaft.
  12.  
  13. Install pinion stopper and stopper clip.
  14.  
  15. Reassemble the front gear case to the yoke and the shift lever to the armature.
  16.  
  17. Install the rear cover through-bolts.
  18.  
  19. Install the solenoid or the magnetic switch.
  20.  

REDUCTION GEAR TYPE
  1. Remove the starter.
  2.  
  3. Remove the solenoid and the torsion spring. Mark the front housing with relationship to the center housing.
  4.  
  5. Remove the center housing-to-front housing bolts, then separate the front housing from the center housing. Do not disassemble the entire starter.
  6.  
  7. Remove the pinion/reduction gear assembly from the armature shaft.
  8.  

It may be necessary to remove the shift lever pivot pin, to disconnect the pinion/reduction gear assembly from the armature shaft.

  1. Installation is the reverse of the removal procedures. The best idea is to try not to disassemble the entire starter when removing the pinion/reduction gear. Do not disturb the brush assembly in the rear cover.
  2.  

 
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