Mitsuba two brush endfloat

[Brendan W]

My starter had no washers and a lot of float. The brushes were riding on the middle of the commutator and the armature was striking the bottom of the power terminal. Operation was a bit hit and miss until last night there was nothing just the relay clicking but no current draw. Bridging the relay did nothing. I have packed the brush end of the armature with 3mm washers and about 2mm at the drive end. Endfloat is now about 2mm and the brushes are close to the outer edge of the comm. Looks good so far.
I also relearned that push starting on gravel is a bad idea

[tom203]

If you still have problems, head to a shop that specializes in auto starters and generator repair- repairing a motorcycle starter is no different.

[Brendan W]

Thanks Tom, I've been there already. They are a good shop usually but packed the drive end probably making it worse. I can find assy drwgs showing washers both ends and a spring washer on the drive side but no info on total stack thicknesses.