"CLICK" and no start

[applewew]

Hi,

Over the last few days the car has been giving issues starting, it will usually make a CLICK sound when I turn the key, at first I only had to try one more time, but this morning I spent 20 minutes trying until it started.

I'm doubting a bit that is the starter failing, since once it works, it works like normal, I understand it could be a starter solenoid issue?

Thanks will be very appreciated, I really don't want to be stranded in the middle of nowhere.

[marlinh]

That is usually a sign of the contacts on the starter pitting. It is an easy and inexpensive fix if you do it yourself. The contacts cost less than five or six dollars. You need to remove the starter to confirm and also do the repair.

[applewew]

Sounds like I found myself something to do tomorrow.

Any chance that it is the solenoid? Should I change / repair both just to make sure?

[marlinh]

I guess it could be the solenoid, but I have found them to be extremely reliable. If you pull the cover off the contacts you will see immediately if they are pitted. If you replace them, they need to be installed square. They tend to twist when you tighten the bolt that holds them in place. Also the plunger needs to be cleaned up. I usually use a small file and carefully file it flat and smooth. Sometimes, the plunger is replaced, but I have had good luck with cleaning the surfaces carefully. Then a bit of brake clean or contact cleaner to wipe down the surface you have filed. The plunger has a spring on it. Don't lose it, and the shaft is greased. If it has a good coating on it, I just reinstall it. Not sure what grease is recommended if it needs it.

Also, before you jump into this job, I am sure you eliminated any bad connections from the battery to the starter. Always check the easy stuff. It is easily overlooked.

[Petros]

First clean the batter cables contacts, both ground and "plus" side, and the other end where the ground strap is bolted to the body, and where the "plus" side cable attaches to the starter. You might also double check both ends of the ground strap for the engine as well.

If those are good than likely it is the contacts inside the solonoid. These starters are pretty reliable, but the high voltage internal contacts are usually the first to go. Mine has be acting up all winter/spring, sometimes works fine, sometimes clicks 3-4 times. Today it must have clicked twenty times before it finally started. I knew if I just kept pounding the bad contact eventually it pound through the corrored contact, but I think I have to fix it this weekend, I can not always part on a hill (which is always my "back up" plan, getting too old to push start it by my self).

[Mark]

I've done this a few times on several cars. Half the time it was the starter brushes. They get worn down over time and the spring behind them can no longer push them out far enough to make reliable contact. I paid about $2 each for new ones. To replace them, you need a soldering iron to remove the old ones and attach the wires to the new ones.
The other half of the time it was the solenoid contacts. They are flat pieces of copper that gradually wear down as a disk rotates on them. They are attached to the other end of the bolts where your wires hook up (The FSM doesn't show the inside of the solenoid). These just cost a few dollars and there's no soldering required to replace them. Once, as a temporary fix, I just shoved a folded piece of paper under them to raise them up a bit so they would contact the disk again.
As mentioned, the FSM doesn't show how to replace them so here's a random link I found that showsthe basics (It's from another vehicle, but the contacts look pretty much the same): The pictures are at the bottom of the page: http://www.sherco-auto.com/contacts.htm

[Mark]

By the way, if you remove the solenoid contacts, be careful not to damage the insulators around them. They're like a black plastic sleeve that insulates them electrically from the solenoid body. They can be very brittle since they're so old. I'm not sure where to get replacements for them.

[applewew]

Hello everyone,

I changed the contacts on the starter solenoid and its working sweet now.

Since I was into it, I also fixed the horn, which would only work when the wheel was rotated.

Thanks a lot

[JesseN]

I am having this problem. What is the best way to get at the bolts holding the starter? Do I go from underneath? How did you get to them and get a good bit of torque?

Thank you so much.

Jesse

[marlinh]

If you can't break the bolts free from the top of the engine, you will probably have to jack it up (secure with jack stands) and get at the bolts from underneath. I usually get away with a six point 14mm socket and a flex handle ratchet to loosen the bolts. If they were really torqued on you may need to use a breaker bar, but usually they aren't that tight. Avoid 12 point wrenches/ sockets unless that is all you have and you are extremely careful that they won't slip. Once the heads of the bolts strip it makes it harder to remove them.