Replacing Kavan Starter Brushes

Jim Johns

Kavan starters work great for starting our SPA engines, and they are now being imported by Sig Manufacturing. They have a planetary gear drive system that allows them to be much smaller in diameter and lighter than convetional starters. Kavan starters do not use a switch per se. One brush is in constant contact with the motor armature, while the other brush is lifted off the armature when the "switch" is in the OFF position. This causes the brushes to wear, and they need to be replaced periodically. Kavan produces a complete brush replacement kit for about $8 that has everything you'll need to get your starter back in good operating condition.

Below is Duane Wilson's Kavan starter on a B&P Products LiPo battery box. This is essentially the same setup as the one I use and show in my battery box tip. After many years, Duane's brushes had worn to the extent that it was virtually impossible to use the starter. You just could not move the brush far enough to contact the armature, so we rebuilt his starter last fall at the Asheville contest. The tag from the brush kit is as the left of the photo.

This photo below shows the inside of the rear end cap of Duane's disassembled starter. Notice two things - the wear on the right brush (yellow arrow) and all the brownish "dust" in the end cap. That dust is actually bits of the powered metal brushes that were ground off by the armature during normal use.

We cleaned out all the "dust, replaced the brushes and his starter was as good as new. Complete instructions (link below) and the necessary reassembly tools are included in the brush kit.

Kavan Brush Replacement Instructions