You should disassemble the starter and thouroughly clean, then inspect all
parts. Pay close attention to the the condition of the copper portion of the
armature where the brushes ride. If the copper strips look smeared and
distorted or even fused together or if the insulation between them is flush
with the copper- try this.
First, polish the copper off with 250 grit wet or dry paper. Use water for
best results and tear the paper in long thin strips so that you can wrap at
least half way around the commutator (copper strips) and never ever stay on
one side for very long. Once the gaps are all even take a sharp piece of
metal and scrape the insulation down so it is a couple of thousandths lower
than the copper.By this time you will have burrs around the edges of the
copper- knock them off with a little sanding. It should improve starter
performance, drastically if commutator was real bad. If you can get at the
brushes with the armature installed in the end plate run 300-350 grit paper
between the brushes and the commutator grit toeard brush to seat them well.
Anyway good luck!
Steve Wawrzyniec
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