Club 80-90 Forums

Hi guys been having problem in which the starter won't always work say works on third go other times starter just click so I've ...
1) new ignition switch
2) charged battery and teued with jump pack
3) fitted 2nd earth between starter and chassis
4) fitted brand new starter
5)changed crimp on end of trigger wire
6)cleaned all contacts
8)starter bush was replaced with gearbox overhaul about 1500 miles ago
9) bulb test on trigger wire lights during key turn

Now it does turn at all let alone intermittently. Can hear solenoid kick in that's it
Any ideas .??

Is the connection plug to ignition switch sound? Try starting and wriggling it. I think you may need to do some continuity checks on this one. Could be anywhere but clearly something isn't making a reliable connection.

Maybe it is worth trying the use of a relay for the trigger wire - I know that several people have done this to rule out voltage drop. I have done it on mine as I experienced problems like that a long time ago. A bit easier on a diesel as the battery is so much closer I know but may help. Have you checked what voltage is on the trigger at the starter when the solenoid is actuated rather than just a continuity check?

Cheers guys some progress
After pulling back the boot on the ring terminal of main battery wite I found very bad corrosion in fact half the strands Werner connected. So chopped that off but now need new. Ring crimp and ideas of old wire size .??

You could find its corroded along the length. Not uncommon if original.

This applies to all vehicles (length of cable dictated by particular setup):

https://club8090.co.uk/wiki/VW ... ain_cables" onclick="window.open(this.href);return false;

Check the voltage on the pull in wire (trigger) at the starter that may give you some clues. Low voltage from voltage drop would cause intermittent cranking or slight clicking.

Jakemate wrote:Check the voltage on the pull in wire (trigger) at the starter that may give you some clues. Low voltage from voltage drop would cause intermittent cranking or slight clicking.

Oldiebut goodie wrote:Maybe it is worth trying the use of a relay for the trigger wire - I know that several people have done this to rule out voltage drop. I have done it on mine as I experienced problems like that a long time ago. A bit easier on a diesel as the battery is so much closer I know but may help. Have you checked what voltage is on the trigger at the starter when the solenoid is actuated rather than just a continuity check?

Cheers guys triggers at about 11v on cranking
Luckily the rest of the wire has no corrosion and is bright clean copper .!

Sorry oldie but goodie, missed that
Good idea sticking a relay in though. Takes the strain off the ignition switch.

Nope still nothing I give up
New starter
All earths cleaned
Extra earths added
New ignition switch
Ring on end of main feed changed
New trigger wire from fuse box to starter
New gearbox bush 1500 miles ago
Fully charged battery

Any other ideas .??

Well without it in front of us I can't suggest anything. Is the battery actually any good? You may be able to charge it but it doesn't follow its up to the job.

Assuming it IS in good order, you need to pinpoint where the problem is, rather than trying everything in the hope that you nail it. If it were me, I'd disconnect rotor from dizzy, make sure gearbox in in neutral and see if I could get that motor to turn with the battery out and jump leads direct to starter in situ. If it works every single time then it has to be a dodgy cable somewhere. If it doesn't work, battery is poo or brushes in motor (new or not) are not making contact all the time.

There are plenty of guides on this on youtube. Look for "starter motor test" or "starter motor testing".

You need to make up a couple of test leads of 2mm cable so they reach outside the rear wheel arch.
Remove the red/black cable from the starter motor and connect one of the test leads in it' place, and connect the other to the main battery lead terminal (don't let it touch the bodywork).
Check it is not in gear then touch the two cables together this should operate the starter motor bypassing the ignition switch.

Ok guys got a result

The starter end of the main power cable had coroded badly causing. Intermittent starting. Upon replacing this. Still wouldn't start turns out its the new starter that's either not manly enough or faulty so refitted old one cranked straight away typical lol
Cheers for the advise .!

If its a new starter, it could be that one of the brushes has detached itself from its connection. Send it back either way.