Club 80-90 Forums

Now then, cleaning up my starter and trying to disassemble (grrrr, need to get an impact driver onto it), I noticed that the 'link wire' between the solenoid and starter has many broken strands. Is this possible to repair DIY or is it something I'll have to get a pro refurbisher to do?

Thanks, mitch.

Depends how many are broken and frayed. You could remove a terminal and put heat shrink around the cable if it's only a few strands or make up a new cable using the same diameter cable.

Take it off and take it to a local 'man in shed' type place. usually only £35 to get the whole thing reconned.

Its soldered and they get corroded. Best job is to get it taken off, cleaned up and new one put on, if you fix it, it will only ever get worst over time. At a guess maybe 15 mins and a few bob to get the strap fixed.

The soldering is all fine, it's about 5 mm after the grommet from the starter casing where the wires are broken. I'd guess that about 75% of the strands are broke! Gutted really, as I was hoping to do the refurb myself as I don't get time to do many 'projects' because I 'own' 2 boys that keep me busy!

I changed the horn the other day, that was quite an accomplishment for me!

Pretty common for the fine copper braided wire to rot away in this way. Obviously a vital component in the function of the starter and as such it isn't worth cutting corners.
This is just an example but companies like this can normally supply the correct brush set providing you can supply a Bosch part number.

http://www.ebay.co.uk/itm/134658-BOSCH- ... 461927343a" onclick="window.open(this.href);return false;

Martin

Like to know what that wire looks like out of the starter
can you get a pic up?
may help to suggest alternatives and repairs

There are numerous Bosch starter videos, even on youtube and whilst not identical to the ones used on the T25, the principles/layout are basically the same. Its just that on ours, there is much more soldering involved. Two of the brushes, and yes, that earth wire. I've got one here dismantled but struggling to get enough light on it to take a piccy.

CovKid wrote:. I've got one here dismantled but struggling to get enough light on it to take a piccy.

go on you know you want to, maybe need to wait for daylight

In fact, its similar to this. Note two brushes and where they're soldered - the earth wire (right) is soldered to same area. The remaining two brushes are in the brush box.

http://www.euro4x4parts.com/images/meca ... ur_009.jpg" onclick="window.open(this.href);return false;

With quite a few starters, all four brushes and the earth wire are as one - on the brush box. Ours are not unfortunately so you need a very heavyweight soldering iron, or a jewellers blowtorch (maplins do an over-priced one for £22 that accepts lighter gas).

However, armed with the right gear, you can soon rebuild one. Most of our starters suffer from corroded earth cable, defunct solenoid, worn brushes or just an accumulation of carbon dust in there. Providing starter isn't completely corroded and bits rusted solid, you can get in there and renew but soldering skills essential I'm afraid.

itchyfeet wrote:Like to know what that wire looks like out of the starter
can you get a pic up?
may help to suggest alternatives and repairs

I'll be with you in the very near future, thus, I'll delight in watching you put a pic up on my behalf! Seriously, been so long since I did it that I've forgotten.

Like this.

Ok cool so m8 ring on one end and soldered the other by the looks
thanks

Yep, that's the critter. Once I get the starter apart, I'll be better able to replace it. Seeing as you folk have already managed to get into your casings, how did you undo the 3 screws that require a large flat bit to undo. I've tried a LARGE screwdiver and muscle (not so large) - no luck. I've resisted applying heat so far and was going to try an impact driver but I don't have a large enough bit for it (not got around to buying one either). I either need a heffalump to put his weight onto the screwdriver or employ a different method.

I have used heat successfully in the past but I wasn't worried about damaging the internals as they weren't quite as rare/expensive as t25 starters.

Can you see my picture for some reason I can't, it just says image.

bigherb wrote:Can you see my picture for some reason I can't, it just says image.

Yep, clear as......