Hi
I thought I had fixed my broken +v bolt.
No circut to the earth side of the bush plate. when on the bench.
Fit the end cap , still on the bench, and there is no circut from =v bush to the plate.

Screw it on to the starter and I get a circut from +v bolt to -v when the end cap is on. Now I thnk this is correct as it would complete the circut thru the copper contacts on the end of the armature.
Is my thinking correct?

All i am getting is a fast ticking from the solenoid and the dash lights go out, like a short when i try to start.
I tried a direct wire to the starter and no action! well some sparks!

So as I may now need to remove the starter completly, can this be done without removing the alternator, which requires the special tool, that I don't have of course, or can I get to the three bolts when i remove the left hand cover?

I will most likely pull the end cap off again just to check any way

ta Nigel

Nigel,

I purchased my alternator wrench from an ebay seller from your neck of the woods for 78.00 au. His ebay id is discusprinlo.

If you do not want to purchase the wrench I have removed the alternator using the below method.

Wrap your alternator with lots of duct tape.

Pick up a chain strap wrench and wrap it on the alternator. Place a rod to brace the strap wrench against the case near the front sprocket.

Use a breaker bar and socket to break loose the alternator nut.

Use this as a last ditch effort, It would be better to go the safer route and get the wrench, but the above steps worked for me.

Cheers

Joe

I have often wondered if the starter could be removed without first removing the left side engine cover.
Take a look at the photo below. Look at the plug that the red asterick is over. It can be removed from the front and then I wounder if the starter bolt can be reached and loosen/tighten by working through the hole after removing the plug? Has anyone tried this?
That would be removing plug #10 to get to screw #6 in the second picture.

Id like to watch you try , hang on and I will get a keg of beer and some groceries to keep me going while you work on it ,ha ha . Sure would be good to be able to do tho as removing covers is a pain

hmmm seems like a plan one day when the cover is off to try it.

Now I have somehow managed to get it working.
I recleaned the copper contacts where the bushes contact and that seems to have done the trick.
I had originally cleaned then with contact cleaner, but that turned them black. Using Deoxide Red they cleaned up better and the starter turned over.

I also think the gel battery may be a bit suspect. It showed 11.5v, but after a few turns it wouldn't turn over past the compression point.
After charging last night it was working a peach this morning.

As a tip I would suggest that before pulling off the end cap [you will need to remove the oil sender and the 19mm bolt below it], put a piece of tape all the way along the starter body . This makes it easy to realign the long bolts. just cut it where it seperates as needed. The first time I spent nearly 1 hour trying to align the holes before I pulled the cover off enough to find the bolt hole. 2nd time about 5 seconds!.
The long bolt closer to the engine will get past the webbing on the case with a small tap!

thanks for your advice and help

actually I don't think you could get enough turn on the allen key thru that gap to get to the next flat, 60degree turn?