Hi guys... thought I'd pick you collective brains and throw this question out to ya's.

The starter in my ute died yet again. I've already replaced the solenoid contacts about a month ago (after reading posts on here). Worked a treat until a couple of days ago. Now it engages into the ring gear and sorta turns the motor over but sounds awful. Then it just dies. No clicks or anything. I give the starter a smack with a BFH and all is good again for the next restart.

I've had the starter of to check the contacts and run it off the battery unbolted from engine. The starter pushes the sprocket out and turns, but gets progresively faster and faster. Then smoke comes out of it.

So... my question is are these things DIY rebuildable or is it something only a shop can fix?

Thanks guys

Do some testing:
- http://www.4crawler.com/4x4/CheapTricks/Starter.shtml#EasyTest

And then if you find the voltage to the solenoid is low, try this:
- http://www.4crawler.com/4x4/CheapTricks/Starter.shtml#OtherOptions

Pretty normal, the starter is a series wound motor. It will continue to speed up until it explodes. The series wound motors are all torque, needed to spin an engine over.

Thanks for the replies guys.

I think I've sussed it out now. I fully stripped the starter motor and there was gunk and crud everywhere. I soaked it all in kerosene to remove the buildup. I noticed that where the brushes contact the spindle on the electric motor, there was a burred over bit that would be jamming up against the brushes.

I hit the spindle with some carby cleaner to clean the contacting surface and filed the burred bit off. The two brushes from the windings in the motor (The + ones I would imagine) were worn and barely contacting the spindle at all. I filed them down and put them back in sideways <img src="/forums/images/graemlins/lol.gif" alt="" /> . A bit ghetto I know but it's a public holiday today and I need the lux tommorow.

I wacked it all back together (with new grease of course) and fired the old girl up. I thought it was gonna rip the flywheel from the crank... lol. I've never heard it that grunty before. It always battle to start the ute on cold mornings (being diesel and all) but seems 10 times better now.

Just thought I'd share. I know when I follow a thread I like to see a resolution from the thread starter.