TOPIC:

Conical spring washers !!! www.avonstainlessfasteners.co.uk/stainle...v0upiiefh0cvgd7ru777

there you go problem solved

Its a bit 'heath robinson' but using 2 nylon rear spacers and dense rubber washers prove the starter and sprag are ok, it just needs more pre load, as the dog slips over on the compression stroke.... another washer !

I just stripped my gear off the end of the spare starter motor, starting from the motor and working out, there is a thrust bearing against a circlip having i/d 15mm, o/d 28mm x 4.8mm thick, then we have the gear with its release clutch facing the nose of the shaft, then we have 6 cup washers i/d 15mm, o/d 32mm x 1.8mm thick, then we have a bearing sleeve for the support bearing were the nose of the shaft enters the housing i/d 11mm, o/d 20mm, x 14.6mm long, both ends of this sleeve are counter bored 16mm diameter x 3.5 depth . there are no spacers in the assembly, if needed I can make and mail you drawings
Cheers
John

Thanks... I just have it apart again, I found a cup washer jammed in the suspension linkage ! so now I have 4, but these sizes are really important,I will try and replicate the dimensions, otherwise I will find another starter in one piece.

Yup, always best to inspect your rear suspension when looking for minor parts that should reside safely bolted within the engine. Some folk should have their tools taken away and their fingers broken so they can't meddle with things they just shouldn't meddle with.
Well done for perseverance and a bit of Sherlock Holmes investigation. Makes repairing the sprag a relative doddle... ;}