starter problem - earth strap so hot I cant touch it

[CovKid]

Yep, its increasingly the case but bad workmanship and/or poor quality control can render 'new' starters dead/dying after just 4-5 months. I've seen three that fit that bill (from different suppliers) and they were not cheap but badly put together inside. Just daft things like a bad solder joint mostly.

Always worth trying to repair the one you've got unless it is a rusted hulk and simply refuses to let you in. A brand new solenoid is nowhere near the cost of a new starter - neither are brushes. Certainly don't assume that an exchange starter will actually be superior to the faulty one in the longer term - even if it looks nice with fresh paint.

I always keep a starter around that I can rebuild if needed. Anything that clearly is on its last legs just gets taken apart, cleaned and used for spares.

[ghost123uk]

Mate of mine just paid over £200 for a recon starter motor for the BIG F0rd Diesel engine in his narrow boat. It was failed after about 4 uses and had to go back.

if you got hot wires, either solenoid is shot or wired it backwards somewhere.

Can't really endorse that diagnosis

[Alex56]

got some heavy duty jump leads and ran them to earth and starter motor from battery, still turned over slow.

Then disconnected battery from van and loom from starter, and ran earth leads direct to starter (not solenoid) and it still turned slowly.

So, the problem appears to be that the reconditioned starter has lasted for about 5 minutes worth of cranking.

Back to GSF in the morning.