Thanks for the offer, turns out it was quite easy to remove the starter...wish I had just opened my eyes a bit before following a video on you tube for a trx 420...turns out the engines are quite different .
All I needed to do was to undo two bolts to remove a small panel and hey presto there it was...three further nuts later and it was in the house being pulled apart to expose a mountain of carbon (or whatever it is) from the inside of the unit.
Hopefully the new parts arrive tomorrow and I can put it all back together.
What condition is the commutator in ? If you put new brushes on scored com they'll arc and wear down. You can put the armature in a battery drill to spin it and give the com a gentle clean with wet and dry on a piece of wood (so it's flat) I know this is a bodge way of doing it (field repair really) but unless you have a lathe it's the easiest way. DON'T take too much off the com, just smooth and clean.
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