as cts has suggested check the gaps btween the comutator segments it lookslike a couple might be bridged and that will cuase problems. clean them gently a bit of shim stock or a old feeler guage can be used.

CTS, Old Magnet, & Trainzkid - I haven't given all of the starter components a good clean yet (will do that next week when I'm armed with some cleaning fluid), so I can check out the the internals properly for wear, bridging on the comutator etc.  The brushes and springs and their leads look to be in ok shape as far as I can see.  Plenty of meat on the brushes and travel in the springs, so they shouldn't be an issue.

There didn't appear to be any slop in the armature shaft either which is good news, no sign of contact of the armature on the field shoes.  It was interesting to see though when I cleaned all the old grease off the bendix gear how much looser that was.  Not badly so, but there is definitely a bit of play in it without all the crap padding it out.

I need a new battery for my multi-meter, but once I have that I will do a resistance check on the armature, make sure there are no shorts.

Here's the really big question though - once I've finished refurbishing it, do I repaint it?!

Hi, LangdonStevenson.
Not unless you're going to paint the whole machine - - - and I'm guessing you won't tknow that until you get it running and find out what other 'suprises' it maght have in store for you, if any.

But I don't get a vote 'coz I yain't rescuin' it.

Just my 0.02.

Deas - I was mostly joking about the painting of the starter   But yes, best to get it running first before deciding if it's going to be a "rat Cat", or "show Cat".

if it was me, I would hit it with some black enamel after refurbishing...when would be a better time?
- but the colour won't affect performance so I suppose whatever your heart desires

Kittyman1 - oh come on now, we all know that red ones go faster!
But if I repaint, then I'd definitely go with the original yellow - I can't come at a black starter motor for some undefined reason.

Langdon - I do not remember if there was discussion on the CCU - Be sure it is functioning before your start the Main Engine - Might save you some added grief.
Paint - I don't think the starter or Cat will be able to discern if it was painted or what color - that well used and cared for "patina" is always a favorite.
Keep up the great work and postings - many here looking forward to that machine "crawlin". As always, photos are greatly appreciated, they tend to tell more than words.
CTS

Hi, LangdonSrevenson.
CTS raises an interesting point about the CCU. That front mounted CCU is driven full time by the engine - might be worth backing off the clutch adjustment before you try to start the diesel to try to avoid getting a rude surprise if the clutches are stuck and the blade suddenly starts lifting.

If the clutch plates are stuck though, there should be a bit of a giveaway when you start turning the diesel with the pilot motor as the blade would start lifting then.

Just my 0.02.

CTS and Deas - It took me a moment to work out what CCU meant (critter capture unit perhaps? Better known as the oil bath air cleaner). But Deas came to my rescue!

No, we haven't talked about the CCU in this thread and that's a fair warning, but given the diesel is definitely going to need some cranking to get the fuel lines primes etc then as Deas says that should give me fair warning if the CCU clutch is stuck.  I'll have to look up how to adjust that clutch so I can do it if required.

Regarding the paint - yes the "well worn" patina is definitely "a look" of its own.  And starting to paint things is a big commitment...

I'm glad you and others are enjoying the ride with this project (and I greatly appreciate everyone's input and help).  Yes the photos make things so much easier and more interesting!  I shot a bunch of video last time I was up with the machine which I'm still editing up, but I'll post a link here when that's done too.

To reassemble the starter motor I am going to need some kind of insulation/seal material to cover the holes in the back of the starter under the cover band. 

 

 In the video I watched of someone renovating a similar starter motor he used some sort of wide black sticky backed material.  He didn't mention what it was and I'm not sure where to start with that.  I could use gasket material, but that's not what it had when I disassembled it - which was a strange multi-layerd plastic material.

Does anyone have any thoughts of what would be the best replacement here to keep the water and dust out?