Car presented not running due to the main engine fuse blowing as soon as the ignition was turned on. Initial investigation showed that the main loom split below the relay box in the engine bay and ran back towards the drivers foot well through the right wheel arch and across the front of the car. It was also noted that due to missing/damaged inner wheel arches the loom was buried in dirt and sand. Initially work was undertaken to clean and inspect the wiring and find possible points where the cable might be chaffing. Chafe point were found where cables were routed under the air filter box. The circuits were teased out and dried, after which the fuse remained intact and the engine started and ran. After repacking the loom and rebuilding the relay box, the car was further tested, proved satisfactory and was returned to its owner. Job Done or so I thought.......
After removing the starter motor from the engine it was tested on the bench and found to be completely dead. Having stripped it, both the brushes and commutator were found to be worn out. To rectify this the commutator was turned down in the lathe undercut between the segments and polished with fine emery cloth. Luckily there was plenty of copper in the segments and it turned up nicely parallel. After thoroughly cleaning the brush plate it was fitted with new brushes and the bearings greased. At this point the casing was cleaned and during the cleaning process one of the permanent magnets fell out and had to be reattached using epoxy resin. Once this had cured the motor was reassembled, tested and refitted to the quad. Job Done!