Hot starter motor solenoid

[boatbuilder]

Ok, so the solenoid on my starter motor is very hot and it looks like the plastic has slightly melted on the solenoid.
It still starts the engine ok, but theres even a wee bit of smoke coming off the solenoid when cranking the engine.

Can you get replacement solenoids or do you have to get the whole starter motor as well?
Its for a 1.6 diesel CS code, 1984.

[colinthefox]

New solenoids are available. See if you can find an alternator/starter motor repair specialist local to you.

But I think it's more likely to be one of the connections with the big fat wires making a poor contact and heating up due to the very large current flowing while cranking.

You could try cranking the engine in total darkness. Usually the faulty connection will light up/fizzle.

The wires are supposed to be secured to the solenoid with a cable tie. This is important. If not, the vibration will damage the connections, possibly resulting in the problem you've been having.

If it's just a poor connection, you should be able to clean it up with abrasive, then smear with copperslip and reassemble, not forgetting the cable tie.