Starter motor problem

1

Hi All


Since installing the suby ej25 on my Syncro  I have had an intermittent issue with the starter.

Once in ten starts it wont engage.

The small starter gear won't engage with the main gear. 

There is a clicking at the starter motor to say it is trying.

The starter motor contact doesn't close (since it is not going in far enough) so it wont turn over.


I have to put the car in gear and manually rock it to re position the gears.


Not normally an issue, until yesterday...

I was on a 45 degree incline negotiating a berm and we stalled (should have used G).

Slid 20 meters back down the hill and into the bank still at a horrible angle. Lots of adrenaline...

The starter failed...oh shit not now! 

It took the winch to scull drag the Syncro in gear to enable the starter.


I have to fix this problem!


So far I have:


Replaced the starter.

Installed a starter relay.

Ran a dedicated 10mm cable directly to the starter for good earthing.

This is not an electrical problem (well I don't think it is).


Should I try installing a Go Westy Gear reduction starter?


Regards


PK


PS: I will write up about a trip to Bendethra (NSW) the back way. 

The story will be called 'How to wreck your Syncro'...




2
Peter,

The standard VW Waterboxer engine has been starting my 6cyl Subaru donk for the last 20 years (I have replaced it twice in that time).

If you use the smallcar bell-housing or similar, I cant see why your Subaru starter wouldnt kick a 2.5L 4 cyl over easily.

IS it a hot start issue??

I had problems where my earth strap would fail when the engine got hot hence earthing to the starter circuit must be in perfect condition to ensure it works.

Maybe a place to check?

Cheers,

Skot

On 11/11/2015 12:47 PM, kestel.p@bigpond.com [Syncro_T3_Australia] wrote:

Hi All


Since installing the suby ej25 on my Syncro I have had an intermittent issue with the starter.

Once in ten starts it wont engage.

The small starter gear won't engage with the main gear.

There is a clicking at the starter motor to say it is trying.

The starter motor contact doesn't close (since it is not going in far enough) so it wont turn over.


I have to put the car in gear and manually rock it to re position the gears.


Not normally an issue, until yesterday...

I was on a 45 degree incline negotiating a berm and we stalled (should have used G).

Slid 20 meters back down the hill and into the bank still at a horrible angle. Lots of adrenaline...

The starter failed...oh shit not now!

It took the winch to scull drag the Syncro in gear to enable the starter.


I have to fix this problem!


So far I have:


Replaced the starter.

Installed a starter relay.

Ran a dedicated 10mm cable directly to the starter for good earthing.

This is not an electrical problem (well I don't think it is).


Should I try installing a Go Westy Gear reduction starter?


Regards


PK


PS: I will write up about a trip to Bendethra (NSW) the back way.

The story will be called 'How to wreck your Syncro'...





3
Is it a Subaru starter ?

Mark
4
Hi Mark

The starter is original VW.

PK
5
The standard starters don't like the heat when they get old, much like myself. They usually come good after they have been allowed to cool down.

Cheers, Roger
6
Hi Rodger

Yes I have noticed the problem gets worse when every thing is hot.
I suspect the main gear expands and the starter motor gear simply won't engage.
The gears simply hit each other.

Now to figure out a solution...

1: Make the main gear smaller.
For this I would have to go back to the manufacturer. 'Hey, can you make the gear smaller....'

2: Stop it all from over heating.
Impossible

3: Make the starter gear smaller.
That could be done I suppose...use a file??

4: Replace the starter with a 'Go Westy' geared unit.
I could ask them to measure the starter gear I suppose. If it is smaller then yes.

5: Live with it. If it all turns to shit, sit down, and wait for things to cool down.

Option 5 is winning.

PK
7

Hi Peter,

Don't seem to be able to open the 6 replies said to have been posted on this subject so please excuse if I double up. I had a similar intermittent starter problem on my wasserboxer T3 and when I sought to get the starter replaced was told they recommended first fitting a relay as the starter was such a pig to get out. This was duly done and it  served me well for a few years and still was when I sold the Syncro. I see you have already tried this fix and now favour solution 5 (Hope and prayer which I should mention my local family planning centre tells me is not a method). When my starter had this frustrating problem I carried a hammer to inflict the old fashioned tap on the solenoid remedy which again got me out of trouble.It could also show there is possibly corrosion on the solenoid terminals. With the clicking noise it reminds me of what you get with a flat battery. I suppose you have eliminated the bleeding obvious? 

 Good luck anyway its so frustrating when a fine vehicle tests your loyalty in this way.

Roger

Melbourne

8

I had the same problem of not starting when hot. Bought a Gowesty geared starter. It works beautifully and looks really well engineered.

Doone

On Nov 13, 2015 4:20 PM, "kestel.p@bigpond.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com> wrote:

Hi Rodger


Yes I have noticed the problem gets worse when every thing is hot.
I suspect the main gear expands and the starter motor gear simply won't engage.
The gears simply hit each other.

Now to figure out a solution...

1: Make the main gear smaller.
For this I would have to go back to the manufacturer. 'Hey, can you make the gear smaller....'

2: Stop it all from over heating.
Impossible

3: Make the starter gear smaller.
That could be done I suppose...use a file??

4: Replace the starter with a 'Go Westy' geared unit.
I could ask them to measure the starter gear I suppose. If it is smaller then yes.

5: Live with it. If it all turns to shit, sit down, and wait for things to cool down.

Option 5 is winning.

PK