starter motor help.
 

Right so whilst taking my engine out I found that the two nuts either side of the live feed to the starter were seized and spun round. At the time (not quite knowing how it was put together) I made nothing of it and just thought I would have to get a second spanner round the nut.

However now I've taken a closer look at it I have come across a few problems, firstly being you cant get a spanner on the second nut.

http://i62.photobucket.com/albums/h1...e/IMG_0131.jpg

Any ideas on how I can get these undone??? I have had a quick look in halfords and they don't seem to sell thin spanners.....

So after failing at that I thought I may as well dismantle the starter in a bid to try and hold the bolt from the inside. I was greeted to this......

http://i62.photobucket.com/albums/h1...e/IMG_0126.jpg

http://i62.photobucket.com/albums/h1...e/IMG_0128.jpg

What I would call a lot of broken hard plastic bits sitting inside, they definitely didn't fall in after opening but I cant find any evidence of where they came from which suggests something has had a big failure and disintegrated??

THEN!!

To top it all off i realised that the positive terminal is in fact meant to be permanently attached to the brush inside the motor and when it swivelled round I inadvertently broke the connection..... and the other copper wire has turned a slight shade of black!

http://i62.photobucket.com/albums/h1...e/IMG_0127.jpg

Now i know alot of you may say just buy a new one, however I am not one to give up and know the terminal can easily be fixed/replaced, what i really need to know is does the presence of the plastic bits mean its going to fail soon enough anyway? The bike was struggling somewhat to start but would always fire up after a 3-5 secs......

I really need you help with this guys!!!

Cheers,

Ash.

Re: starter motor help.....
 

If you need thin spanners and cant find any, carefully bench (preferably) or angle (rough bugger!) grind an old spanner to suit ;)

Re: starter motor help.....
 

Its not the insulating spacer that goes between the inside of the casing and the stud is it? You may have mashed it when the stud rotated......
Unless your as tight as me looks like you'll need a new brush with wire (change both brushes together?) and that spacer. I'd stick with repairing it but do make sure that every connection surface is really clean and well tightened up to prevent overheating. glang

Re: starter motor help.....
 

Those black bits inside are either chunks of carbon from brushes or bits of insulator from positive post.