Pinon teeth binding, discolouration at the roller freewheel (pinon) and armature shaft due to overheating (internally: Plastic engaging lever running hot or melted. Armature destroyed, collector and armature winding partially spun upwards).

POSSIBLE CAUSE

Permanent or occasional jamming of the starer swtich. i.e. the starter pinon remains engaged even after starting the vehicle. The grease in the free-wheel roller is overstressed by the increased movement that occurs, resulting in an excessive temperature, causing it to decmopose. The pinon bearing sleeve frets against the armature shaft. The increased starter motor revolution speeds exceeds the overspeed of the armatur , which can also cause the commutator and armature winding to be destroyed.

RECTIFICATION

Replace ingition lock / contact part.