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.