[rob_macca67]

Guys...

Been a while since posting here but I've managed to get my old '93 Vitara re-registered for my daughter to start driving it. Recently we are having some starter issues where it sounds like the starter is not engaging the fly-wheel. Have others found this or is this a common issue with age (zook has about 330k on the clock)?

What causes this sort of Issue as the Starter turns over but sounds like it's just not engaging?

I have a spare starter motor but when I tested it - the cog doesn't fly out to engage the starter motor so I'm thinking this is no good as well

The obvious solution is just to buy a new one but are these starters repairable and are they worth repairing?

thanks in advance....

RobM

[Antman]

Hi RobM I don't know if it is more common with zooks, but all starters will do it eventually AFAIK. Hit it with a hammer to get yourself out of a jam, but sounds like it needs replacing. About 25 years ago when I was doing work experience for an Auto Elec I rebuilt a few, but from what a new one would cost I don't think its worth doing.

[sideways]

You could pull it and figure out what the problem is for sure but new starters are $75 on eBay and unless I was in a time crunch, I'd never bother stuffing around with old starters for that much.

At worst it could also be a worn flywheel ring gear. On my Sierra I pressed the ring gear off, flipped it around and pressed it back on a different spot because the teeth were more than half worn away. A 4cyl stops in 2 different spots so those teeth cop a flogging.

[rob_macca67]

Yeah... upon doing a bit more research it's easier just to buy a new one and fit that... will pull the old one apart but I think it will be the solenoid that is the problem...

[fordem]

If the starter is spinning, the chances of it being the solenoid are slim to nil, the bendix (the cog or gear) is not just a gear, it's an overrunning clutch and they have been known to slip.

[rob_macca67]

fordem wrote:

If the starter is spinning, the chances of it being the solenoid are slim to nil, the bendix (the cog or gear) is not just a gear, it's an overrunning clutch and they have been known to slip.

Yeah - It's was the Solenoid that was causing the issue as it wasn't pulling the internal lever enough for the cog to engage the flywheel...

[rob_macca67]

Well... what a complete PITA... Installed the NEW AutoNova Starter Motor from OnlineAutoParts and it did work except for the HUGE LOUD Squeal it made when starting the engine. It was loud to the point that the daughter did not want to drive it. I rang OnlineAutoParts and they gave me another one. I had my doubts about whether the new one would be any different so I took apart a spare starter I had lying around and cleaned it up, removed the new solenoid off the 1st new starter motor that I got off OAP and installed that. It worked perfectly on the 1st start but then failed to start on the 2nd attempt. Out with the spare and in with the 2nd NEW one and as I expected - it started the engine but again the loud squealing noise was still again.
This time I removed it and then pulled apart the SPARE starter to see if I had made a mistake in assembly... which I did. The plastic lever I had installed it in the wrong direction. Re-assembled it and installed it again and this time all worked 100%.

This brings me to a question here for those in the know... Has or is anyone running one of the OnlineAutoParts Starter Motors in their Vitaras? Would like to hear your experience with them...

Starter Motor details:
Brand: AutoNova (5yr Warranty)
Model: ZPN31573 (SMN561)
No of Teeth on Cog: 9

The OEM starters have 8 teeth on the cogs and are much larger in size as the Aftermarket ones which have 9 teeth & have a smaller motor and have reduction gears to help turn over the flywheel. According to OAP - this model starter suits both 8 & 9 teeth cog versions