[Paul Workman]

Originally Posted by ghlkal

Thanks Jim, Cliff, and Paul.


So, Paul, the starter solenoid requires more current that can be supplied if the contacts and loads leading up to the solenoid introduce too much resistance. (true?)

Actually, the resistance (to current flow) of the solenoid is quite low - resulting in ~ 10 amperes (IIRC), which can/does "cook" the (tiny) clutch switch contacts; pitting/eroding them until they become intermittent or fail completely.

Originally Posted by ghlkal

I have my clutch switch bypassed, but I still experience an occasional no start.

Then the internal solenoid contacts in the starter are "cooked". It happens, and is considered a normal replacement item like brake pads or tires. For under $10 you can buy a (Denso starter) kit to replace the worn contacts. But, installing an auxiliary relay will have NO effect on those internal solenoid contacts.

And, if you've bypassed the clutch switch, there's NO advantage to installing the relay mod. (In fact, if you don't intend to remove the clutch switch bypass, installing the auxiliary relay would serve no purpose and actually decrease reliability by introducing an additional (do nothing) component that could fail.

Originally Posted by ghlkal

I plan on doing the relay fix anyway. I'm also going to follow ZR-71's thread where rather than cutting the purple wire in the loom under the hood, he routed from the under the dash disconnecting wires from the clutch switch.


Here's my plan


mount new relay under dash --

pin 30 [high power in] -- new red 12ga wire from battery block
pin 87 [high power out] -- purple wire at clutch switch
pin 85 [low power ground] -- to ground
ping 88 [low power trigger] -- yellow/black wire at clutch switch


pins 30 and 87 are the "high power / battery voltage" legs of the relay
pins 85 and 86 are the "lower current / trigger" legs of the relay


So, the yellow/black wire which comes from the existing starter enable relay will send the signal to trigger the relay and provide battery power through the purple wire to the starter solenoid.

Keeping the bypass? Then FORGET ABOUT INSTALLING THAT RELAY unless you intend to remove the (nanny) clutch switch bypass in the future.