Forum:
Over the last month or so my Fourtrak (2.8 non turbo diesel) has a very intermittent starting problem.
There is a fairly large clunk from either a relay or the starter solenoid, but the starter motor fails to rotate (good battery).
Eventually after trying the key a few times, the starter motor will spin up.
Anyone had this problem before?
Is it likely to be worn brushes / commutator or a sticking pivot on the pre-engaged starter?
Thanks.
Starting Problem
It sounds as though the current going to the solenoid and starter is either loose or corroded.
Check and clean all the connections before looking at replacement. If loose they can short and will generate heat, all must be tight and clean. Ckeck the battery terminals for the same as that will also cause this type of intermittent problem. If you have the green corrosive crust on the terminal clean that off 100% and coat rhe terminals and clamps with vasaline or copperslip to avoid futher problems.
If that fails then look toward a replacement unit for the starter which includes the solenoid as it will be of pre-engaged type.
Good luck
OLDMINIMAN
M J Young
Starting probs
Hi. I have had my f78 independent for 2 years and have had the same problems. My locks have been changed before i bought it, what I have done which has worked for me, is disconnect the battery, squirt some good quality switch cleaner / electrical contact cleaner down the centre of the igition barrel, where the key goes in , and switch on and off about 20 times, it has worked for me lots of times, i usually have to do it about once every 3 months, sometimes longer. You have to disconnect battery otherwise the glow plug relay will go scatty, which is the clicking sound you can hear ,comes from the nearside inner wing which is where the relay is. If you use alot of the cleaner you wiil soon know as it will run out behind the lock and drop on the carpet. Hope that helps, let us know how you get on. Cheers.Hatsu
two possibiltys??
i think the problem your having is a sticky solonoid its not a problem and will in general always work, have you been off roading playing in water etc?? you can take them apart and clean them but might only be a temporary cure, milners do new starters for £130 i think, sometimes a tap on the thing with a hammer will work. the other possibility but i doubt it is lack of volts to the starter, you can check this with a meter and get someone to turn the key as you probe the power and earth of the starter as long as you get about 13v its fine. if it is the solonoid sticking sometimes they actually clear themselves and never do it again - had that happen on a few machines, its not the end of world anyway!!!
Full of ideas but no time to do them!!
www.bloodredoffroad.com
www.milneroffroad.com
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youtube: Redfourtrack
Sticky solenoid
I've been in water - but not more than 6" (if that) at low speed.
Interestingly tonight, it didn't start, and I just kept the key on the start position, and after about maybe 10secs the starter sprung into life!
1985 Veg oil burning Fourtrak "Rocky".
1985 Veg oil burning Fourtrak "Rocky".
STARTING
Interesting about being in water as although it was not deep you would possibly have chucked some water up. Gunge on the connectors be it old dirt or verdi grease, green, will hold water droplets which will not aid starting. If these termonal warm as they may well have done with the ign. on for 10 sec this may have been sifficient to dry off any moisture. The amount of moisture or corrosion only needs to be very slight to cause the problem you are having. I still think tmy earlier answer may be the cause and I would remove, as said , all contacts and clean them up and then smear them with copper slip to avoid corrosion.
OLDMINIMAN
M J Young
Clean.
Clean and vasoline all connections from battery to the starter, include the battery terminals. Clean and vasoline all leads to/from starter, including their route. Also check and clean the earth leads from engine to bodywork. The earth connection to bodywork is often corroded.
When cleaned try the starter.
Whilst the starter is disconnected you could connect the starter direct to the battery's + and - terminals. If it 'clunks' then either the solenoid is breaking down or the starter's internal wiring is faulty. Possibly the starter's carbon brushes need renewing .... much cheaper than a new starter motor and an easy job done.
You can get a 'clunk' if the battery is weak - insufficient amps the torque the starter. This results in the 'clunk' - enough to engage the starter's dog [clunk] into the fly wheel but not enough power to turn the engine. Holding the key in 'on' position will sometimes give a time lapse which allows the battery to build power and the engine 'turns'. Sign of a failing battery.
Test ... switch on headlights and try the starter. Do the headlights noticably dim?
Try fully charging the battery and try the starter.
Started
Usually it is worn brushes on these, these can be obtained from your local auto electrician for about £7.00, replacement is a simple procedure but beware of damaging the brush holders, on some models they are plastic, on others, a paxolin type material.
Solonoid's are not usually prone to problems, but it would be prudent to dismantle it carefully and clean it out, flatten out any pitting on the contacts with a fine file, and apply a thin smear of grease to everything but the contacts.
Earth straps sometimes cause these problems, ther corrode through, or partially through, Vehicle Wiring Products supply this in lengths, along with many different end connectors. Make a new one if yours is damaged, crimp and solder the terminals on, this will ensure a good earth to the engine.