1997+ Mercury 35/40HP 2 Cylinder Outboards Service Manual PN 90-826148R2, Page 91Get this manual
4Remove components from armature bClean the commutator slots after undercuttingcDe-burr the commutator lightly with No00 sandpaper, then clean the commutatordCheck the armature on growler for shortsSee "TESTING", following9Open-circuited armatures often can be saved where and open circuit is obvious and repairableThe most likely place for an open circuit is at the commutator barsLong cranking periods overheat the starter motor so that solder in the connections meltsThe poor connections cause arcing and burning of the commutator bars10Repair bars, that are not too badly burned, by resoldering the leads in bars (using rosin flux solder) and turning down the commutator in lathe to remove burned material, then undercut the mica11Clean out the copper or brush dust from slots between the commutator bars12Check the armature for shorts and groundSee "TESTING"
11658 Spacer Spring Drive Assembly Drive End Cap Armature Shaft Washer
Cleaning and Inspection