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D4 pony starter

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3 years 6 months ago #223074 by Aphelps20
D4 pony starter was created by Aphelps20
Hello everyone
I need to have the starter rebuilt on my d4 7u pony motor. Wondering how to pull the starter out? Any special tricks?

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3 years 6 months ago #223078 by Vance Nickerson
Replied by Vance Nickerson on topic D4 pony starter
One big set screw or hex bolt and the battery cable. Careful pulling it i got distracted and left some blood. The little thing is heavier than it looks.

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3 years 6 months ago #223082 by d2gary
Replied by d2gary on topic D4 pony starter
All of them that I've dealt with there was rust between the housing and the starter nose cone. They can be stuck pretty good, but ive been able to carefully use wedges and pry bars to loosen them. If you take the lock bolt out you can get some penetrant in there to help. Once you have it out polish up the mating surfaces and apply some antiseize to the surfaces.
The following user(s) said Thank You: Aphelps20

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3 years 6 months ago #223084 by Aphelps20
Replied by Aphelps20 on topic D4 pony starter
I'll give it try tomorrow! Thanks

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3 years 6 months ago #223085 by ag-mike
Replied by ag-mike on topic D4 pony starter
Don't use a rubber or deadblow hammer on the brush end of the starter. Chances are you'll break the bendix casting. Very hard to find replacement. Go easy with handheld propane torch around the casting holding the bendix housing.

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3 years 6 months ago #223086 by neil
Replied by neil on topic D4 pony starter
The large set screw needs to be removed first. I added penetrating oil, then carefully heated the circular bracket with my gas torch and gently tapped the motor out. After it was out, I used some coarse grit sandpaper and cleaned up the bracket and motor surfaces until they'd test-fit well, and then liberally coated with copper anti-seize. Also did this to the belt pulley on the drive.

Cheers,
Neil

Pittsford, NY

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3 years 6 months ago #223089 by neil
Replied by neil on topic D4 pony starter
There's a picture of one on feebay that will show you what it looks like on the OD of the motor housing. The two raised flanges are what rust up along with the corresponding surfaces on the bracket. But as you can see, when loose, it will just slide out. You can also see the depression into which the retaining bolt screws.
Search for "D2 caterpillar pony moter starter"

Cheers,
Neil

Pittsford, NY

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3 years 5 months ago #223259 by trainzkid88
Replied by trainzkid88 on topic D4 pony starter
as others have said grease and anti seize a mechanics friend. graphite grease and nickel anti seize are the best to use.
you can get away with high temp bearing grease in a pinch.
want to seal gaskets and still be able to remove and reuse them a light smear of bearing grease ideal on inspection covers.
dad was taught to use graphite grease on travelling irrigator water cannon nozzles if the threads hadn't been greased when last worked on you would be there forever and possibly break things, when greased you only cracked em free with a wrench they would undo with your fingers.

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