Club 80-90 Forums

That solenoid trigger connector spade is probably the TOP reason for starting problems.
People replace it but only 'crimp' on a new spade with basic terminal pliers, NOT GOOD ENOUGH!

The reasoning your mechanic friend gives for NOT believing this is the cause is sound but in reality the clicking is the solenoid unsuccessfully pushing the pinion into mesh and making 'good contact' to switch the power to the motor.
This action still requires a fair amperage (obviously not on the same scale as the motor itself) but several amps all the same and if this connection is poor then the solenoid makes a half hearted attempt to 'engage and connect but not a fully successful one.

Although very awkward I would solder this connection or at least use professional crimping pliers (the ratchet type)

Martin

California Dreamin wrote: Although very awkward I would solder this connection or at least use professional crimping pliers (the ratchet type)

Martin

Thanks Martin - the idea of soldering that connection was mentioned, so I think that will have to be next on my list

Van been sat overnight, so will pop out and see if she starts in a minute......

started 1st time, then:-

no start
no start
started again

Frankly it can sit outside until I feel in the mood, grrrrrr

frankly, you need to be cleaning the male spade connection on the starter , much more important than which brand of crimp pliers you used! Soldering would be better, however, if you are going to need to solder it, you would be well advised to replace the signal wire from the keyswitch through to the starter with new, as these wires go high resistance with age- easily spotted by the copper core strands going black.

the gearbox nose earth and the battery earth are just as important, cleaning where they attacth to bare metal
i would replace both earth straps before condemning the starter motor completely.

Hi All,

Or you could try and fit one of these............hot start relay kits.

http://www.thesamba.com/vw/classifieds/ ... id=1066289" onclick="window.open(this.href);return false;

Eliminates the ignition switch sending amps to the solenoid, worth a try maybe. Easy enough to make your own.
I have one fitted and it really is easy to install.( Yeah I know.......but I was bored, reading the Samba too much and I am easliy led! )

Good luck.
Mark.

...so far so good....

..and now, back to square 1!!!!
Only starts about 20% of goes, doesnt seem to matter if its early morning, or hot / cold starts etc.
Am currently under van going through the options again. Going to take off the starter and get it bench tested - then go from there.

The mechanic recons we could try running a new wire straight back to the ignition switch (as per aboove suggestion ) to try to eliminate or prove a problem with that wiring.

..Keep calm and carry on! At least its not raining !!

ok, so have removed starter, and its been bench tested repeatedly, and it works every time.
So, as the ignition end of the wiring has been checked out ok, it would seem that the problem lies with the wiring from the push fit block behind the fuse box, to the exciter wire at the solenoid (??) - so we plan to put in a temporary wire from the two places and see if that gets rid of the problem. If it does, then either a rewire of the original run, or a hot start relay will be made up and installed.
I really hope this solves it!

Mocki wrote:frankly, you need to be cleaning the male spade connection on the starter , much more important than which brand of crimp pliers you used! Soldering would be better, however, if you are going to need to solder it, you would be well advised to replace the signal wire from the keyswitch through to the starter with new, as these wires go high resistance with age- easily spotted by the copper core strands going black.

the gearbox nose earth and the battery earth are just as important, cleaning where they attacth to bare metal
i would replace both earth straps before condemning the starter motor completely.

And it seems the prize goes to.... Mocki!
The guys at the local motor factors were convinced it would be an earth problem too. So I (again) took off my nice shiney eath straps from battery and gearbox nose, and took them to show them. They do look in very good condition but as I was told " there's no way to tell what corrosion is under the crimped area, or what resistance change may have taken place over the last 26 years'. So, they used them as templates and made me a pair of new straps.
Fitted them last night, refitted the starter, and hey presto!
Am keeping everything crossed but so far van has started every time.

I guess only time will tell now!

(Have also made up an independant exciter wire, which will run from the ignition block behind the fuse box to the solenoid, should the problem still exist, and I can try that!)

Thanks again for all the advice. And Mocki - I bow down to your greater knowledge! (Beer's on me!)

Happy camper now..... for the moment!