yeah, they do hurt a little. would have helped if I didnt clip my nails the other day.

I tried putting it together that way you would normally think it would go - opposite of removal and that was not working out, drove me to cuss.

So I found little holes next to each brush and used a peice of welding rod in them to hold the wire for the brush in, which held the brush in the holder. Then I got a socket the same size as the commutator and worked that in to hold the brushes deep in their pockets. Put it in the can and pushed the assembly up from the bottom and pushed the socket out of the way, worked pretty good but took me a few tries to get to that point.

 

Just a guess but it sounds like you might have sand and rocks rolling around inside of it.[img]i/expressions/face-icon-small-tongue.gif[/img]

 

That sounded great warrior, I was lazy and took mine to a shop that rebuilds electric motors for us at work. There supposed to let me know if its rebuildable.

Sixsixt, I thought the same thing at first but the starter is shot. I think the brushes or magnets are in pieces and are rolling around. [img]i/expressions/face-icon-small-sad.gif[/img]

 

Sounds like you got it real hot and the armature expanded.

 

Well I got my Starter back today. It was in about 3 bags. One was full of dust. Everything is ruined. So looks like I have to buy a new one.[img]i/expressions/face-icon-small-sad.gif[/img]

 

Bummer. $235 from Yamaha or $150 from Eastcoast ATV. Probably some other places to get one cheaper.