Club 80-90 Forums

Hello everyone, our van has had an intermittent starting problem since we bought it 2 years ago.

The old and very rusted starter motor was replaced with a new one 3 months ago and at first started ok, but recently has failed to start straightaway. Lots of clicking but no starting.

The van has a new battery and new post connectors and two new earth straps (battery and gearbox) bolted to clean metal.

I cleaned up the cable ends and connectors at the solenoid and at the battery. The battery shows 12.9V and with engine running around 14V.

When the ignition key is turned the solenoid clicks each time but it takes several attempts to fire up the starter motor.

I have a new ignition switch ready to install.

I am also thinking of replacing the thick black cable and the red/black exciter wire. A question, does the exciter wire at the solenoid connect directly to the +ive terminal at the battery as does the thick black cable.

I have a Haynes manual but can't understand the wiring diagrams.

Your help would be much appreciated.

Sounds like the starter solinoid is sticking to me. If it was me i would take the starter off and dismantle the solinoid regrease etc and put back in, also check the drive gear,might have some damage preventing it from engaging in the flywheel? You,ve done everything else with the electrics,so cant be much else.

forgot to say you could also test it on the bench to make sure it works well out of the bus. could just be the bush at the end of the drive gear that needs a little grease?

Fit a starter relay, that would eliminate and help the old wiring and connections from the ignition switch.
Easy enough, mount it here you can then pull the red black wire through from the starter motor.

Hi bigherb, thank you for suggesting a starter relay and posting the pic.

Sounds to me to be the best option. You said it was an easy job but it does look a bit challenging for me. I am thinking of getting Curd Brothers in Tunbridge Wells to do it and get them to fit another relay to beef up the head lights, which I replaced last year with only a small improvement in brightness.

Also, I have a new ignition switch as like most parts on the van it may well be the original and I may get Curds to fit that as well.

What do you think?

chapperss wrote:forgot to say you could also test it on the bench to make sure it works well out of the bus. could just be the bush at the end of the drive gear that needs a little grease?

I thought that this was a no-no due to the fact that the petrol starters are not supported at the end?