startermotor question

[agentpineapple]

i'm trying to replace the nut and bolt on a starter motor, the old one was totally corroded and had to be cut off. what a pig of a job to get all the magnets back in place....
my question is this, on the link to the ron ayers micro fiche below, on the top right of the picture there are 3 washers, are they all the same, in the picture, one looks bigger than the other two, more or less the same as the other end, this time 2 thick and one thin washer.
when I took the starter motor apart, it seems I only have thin washers....
my final question regards the new bolt I've fitted, in the micro fiche picture there are an assortment of washers, 4 to be exact and one o-ring, these were all destroyed when cutting the old bolt out, it looks like I will at least have to buy a new o-ring...
but as for the 4 washers, I've had to put a washer and ni-loc nut on the outside of the new bolt to secure it in place, will it be ok to put the main power cable against the ni-loc nut, or am I asking for trouble, considering the electrickery that will be travelling thru it.
all and any advice welcomed.
http://www.ronayers.com/STARTER-MOTOR-C175565.aspx

[popkat]

Not looked at the link but I can't see a problem with bolting the cable on without an o ring, I wouldn't use the nyloc though as it may melt, just run a nut on then the cable and another nut to fix it, this is how most starter motors fix. I would try to get a couple of flanged nuts the type with a serrated surface on the flat as they have a locking type effect

Unless someone else knows a reason why Honda used an o ring and 4 washers.

[VTRDark]

It could be for the rubber boot's lip to clip over and be held in place and possibly help debris from getting in from underneath it, kinda like a plug or cap. Small washer or two to create a slight gap from the main body, then a slightly larger washer for the boot to clip around and then a smaller washer to create a gap so it's not butt up against the bigger washer, then the nut, cable terminal, then on goes the last nut.

Some pics here that might help Marty.
http://www.vtr1000.org/phpBB3/viewtopic ... 15#p230910

(:-})

[sirch345]

For O rings, I think these are the size you want Marty:-
http://www.ebay.co.uk/itm/4mm-x-2mm-Rub ... 20df4f4139

I take it you realise the washers you are talking about are fibre washers so the new bolt is insulated from the starter motor body

Carl could be right about the bigger fibre washer there for the rubber boot to slip over and hod in place.

Chris.

[tony.mon]

You need one on the inside, insulating the bolt head (square/rectangular headed to stop it turning) one acting as a sleeve that the bolt slides through, and another on the outside insulating the nut from contacting the body of the motor.

It's a good idea to then have a spring or sprag washer under the nut head to prevent it loosening.
The sleeve can be any bit of plastic tube, as long as it'll stand the heat. I've used airline tubing before, it goes brittle and needs replacing each time you undo the nut, though.