Starting cafe racer restoration Commando 850 MK3 from Spain

Not necessarily, you would have to replace the plungers as the pads are not available separately.

Also, you should have found a white nylon 'abutment' inside each plunger with the wide end to the spring.

Yes inside each plunger I see a white nylon pin but I cannot take it out. I will order two kits P/CHAIN TENSIONER PLUNGER (69.0622) ref. 06.5341
which includes plunger, spring and the nylon pin.
Is this the "abutment" you talk about?
Or do I also have to order this TENSIONER ABUTMENT ref. 06.5341D ???
 
I disassembled the starter motor, it is is very wasted. I cleaned it and my plan is to fit a four brush conversion kit, new shims, new STARTER MOTOR HEAD ASSEMBLY ref. 06.6312
New O ring.
But the bronze bearing located at the drive end cover is worn-out but I find very difficult to replace it. And I cannot find a new drive cover so I will have to install the old one.
 

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Is this the "abutment" you talk about?
Yes, that is what AN refers to as the "abutment" and what you should have found inside each plunger?
But the bronze bearing located at the drive end cover is worn-out but I find very difficult to replace it. And I cannot find a new drive cover so I will have to install the old one.

Do you mean difficult to find a replacement bearing (bush/bushing) as I believe it is possible to convert it to a ball or needle roller bearing but some machining of the armature and cap could be required.
 
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I can machine the original armature end cap to remove the worn bushing and then insert a new bronze one or a needle roller. Problem is that then the end cap will be open and dirt can eventually penetrate because it will be tough to me to made and solder an aluminium cap.
 
I can machine the original armature end cap to remove the worn bushing and then insert a new bronze one or a needle roller. Problem is that then the end cap will be open and dirt can eventually penetrate because it will be tough to me to made and solder an aluminium cap.
Ok, as you said "drive end" not the armature cap.

You could try cutting a thread in the bush and use a bolt, etc. to extract it or split the bush with a Dremel type cutter (edit link, below) or if the cap is heated enough then the bush could drop or be 'shocked' out. Surely you could machine the cap without having to bore right through it.
Edit
 
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With patient and a dremmel I have been able to remove the bushing. I will look for a new bronze one.
Regarding the drive end I will order a complete new assembly because although it is easy to extract the bushing it also has a special rubber seal and I do not see the spare at Andover neither at RGM.
 
Regarding the drive end I will order a complete new assembly because although it is easy to extract the bushing it also has a special rubber seal and I do not see the spare at Andover neither at RGM.

Both Andover Norton and RGM are out of stock.

The seal appears to be an ordinary garter spring oil seal, probably a standard (Imperial?) size and nothing special about it that I can see.
 
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?
 
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?

First I suggest you measure the shaft and housing diameters (and housing depth) and see if there's a close metric equivalent or one that would fit with a little machining of the housing. The seal only prevents primary case oil mist and splash from entering the starter motor so I doubt the actual armature shaft seal diameter is critical.

Once you know the size (assuming it is Imperial as it's a USA-manufactured Presolite starter motor) then obtaining a seal should not be too difficult, that is if the seal does actually need replacing.
https://www.bearingsrus.co.uk/seali...Kd5LspPLnNY8AWFsjf3AAD6TWxcpBbSRoCGAUQAvD_BwE
 
My problem is that your standard imperial is totally non-standard and difficult to find in my Spanish metric world. I am able to source any kind of metric component but I have no clue about where and what reference to look on imperial one. Could you give a clue or link about a place o places to find these kind of components?
With a magnifying glass, you can usually read the number off any seal and search the internet for that number. Also, I have no direct knowledge of that seal, but it could be metric even though in an imperial device and it's very unlikely to be a non-standard seal.
 
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