Especially when hot. The last time I started it I could also smell electrical smoke from the starter area. I'm guessing it's the starter clutch mechanism?? If so, what parts am I likely to need to fix it (98 S1w) Could it be anything else??

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Everything looks good inside the primary. In fact it looks brand new, I guess Maz is the only person who has been in here before

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I've had to clean the contacts in my solenoid in the past, might be prudent to have a look now you're that far into it

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Last year I joined a group for anti-social people
We haven't met yet.

Will do, although pretty sure it's not the cause, it was definitely metal grinding on metal

PS - It's great working on a motor only Maz has worked on, nothing is seized, no rounded nuts, everything is correct, gasket slipped straight off

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But it's not going to be Maz putting it back together now...is it.

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I hate being strapped for cash....but it pays the bills

Unfortunately no, and bits he didn't touch, e.g starter motor wiring bolt, are in more of a traditional state for me, ie rusted solid and a bugger to reach Anyway, better to learn for myself in the long run.

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OK, now I'm stumped. Starter is in bits. It's very dirty inside, but I can't see anything obviously wrong

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This is either it, or I'm clutching straws. Is this bearing housing in the end cover supposed to have a groove in it

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Sprag clutch.....which you haven't got to yet

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

Ta, Is that No 12 in the manual (figure 5-26), ie Drive assembly/ overrunning clutch

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Yep.

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

I was wondering how to get it out, so I held my breath and hit it with a rubber mallet. How do I tell if it's fooked? It feels a bit stiff, so I guess this is the problem

I've seen them online, is there a recommended source/brand, and also, would I be just as well getting a whole new starter motor unit, they don't seem particularly expensive

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Starting often with a flat battery tends to bugger them up. It should spin free one way, and grip the other. It's lots of little cams with a spring around them. Clever little things

Yes, it's not exactly spinning free, very stiff. Being as the starter motor is looking a bit tired inside I've ordered a complete new starter motor unit, it's not a great deal more expensive than just getting a clutch unit.

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[quote="Bonzo"][quote="Mickrick"]Starting often with a flat battery tends to bugger them up. It should spin free one way, and grip the other. It's lots of little cams with a spring around them. Clever little things [/quote]

Yes, it's not exactly spinning free, very stiff. Being as the starter motor is looking a bit tired inside I've ordered a complete new starter motor unit, it's not a great deal more expensive than just getting a clutch unit.[/quote]
So now you can take the sprag apart, and see how they work