Starter solenoid rebuild-sometimes things just go bad to worse! - ZR-1 Net Registry Forums

secondchance · 06-26-2017

Symptom: Starter wouldn’t turn when heat soaked and yet you can see the volt gauge drop due to current flow.

This starter was installed in Fall of 2012 and logged about 50,000 miles.

Rather than spending $200 on a new starter, I thought I would give a shot at rebuilding the solenoid. Sounds easy enough. Right?

Once again, the plenum comes off, plug wires disconnected, ignition coils and the coil tray removed and pulled the starter. So far, I have about one hour into this.

3 bolts removed from the solenoid plunger cover, cover popped off revealing the plunger and contact plates.

Replaced both contacts and ready for reassembly.

Old contact plates were worn down where the plunger had made contact. Interesting to note that one side wore more than the other side.

Got everything back together, intake plenum lined up, plenum bolts in. Looking for my torque wrench, I see two starter solenoid plungers - oneold and one new. Noooooo! I removed the plunger to take a pic showing two newcontact plates and must have forgotten to reinstall the plunger before closing it up… S**t!!!

So, I go through top end disassembly all over again, pull the starter, remove solenoid cover, install the plunger, the cover, back in the valley followed by coil base.

10 mm head bolt (M6?) to fasten ignition coil base, passenger side back, I had the bolt double side taped to a socket with u-joint to start threading. As I am bring the contraption to line up, the bolt drops right above the intake runners. I had all runners plugged with paper towels when I did this the first time. Second time around, with all the frustration of having to do the same again, I over looked closing off the injector housing openings. Now I am not sure whether the bolt went into the intake or dropped in the engine V. Out of frustration I call Jagdpanzer to consult. ‘Course, calm and collected Phil tells me to get a pencil magnet and fish all the IH intakes.

I drive out to Advance Auto Parts, buy a couple of magnets on bendable goosenecks. As I am going through each intakes I get to cylinder #3, secondaryintake, I hear that “click” as the magnet gets hold of the missing bolt! Whew!!!

Another hour and a half and finally everything is buttoned up. Sure was a day of hell!

Hopefully, solenoid rebuild has fixed periodic non-start issue.

06-26-2017	#1
secondchance Join Date: Aug 2006 Location: McLean, VA Posts: 3,717	Starter solenoid rebuild-sometimes things just go bad to worse! Symptom: Starter wouldn’t turn when heat soaked and yet you can see the volt gauge drop due to current flow. This starter was installed in Fall of 2012 and logged about 50,000 miles. Rather than spending $200 on a new starter, I thought I would give a shot at rebuilding the solenoid. Sounds easy enough. Right? Once again, the plenum comes off, plug wires disconnected, ignition coils and the coil tray removed and pulled the starter. So far, I have about one hour into this. 3 bolts removed from the solenoid plunger cover, cover popped off revealing the plunger and contact plates. Replaced both contacts and ready for reassembly. Old contact plates were worn down where the plunger had made contact. Interesting to note that one side wore more than the other side. Got everything back together, intake plenum lined up, plenum bolts in. Looking for my torque wrench, I see two starter solenoid plungers - oneold and one new. Noooooo! I removed the plunger to take a pic showing two newcontact plates and must have forgotten to reinstall the plunger before closing it up… S*t!!! So, I go through top end disassembly all over again, pull the starter, remove solenoid cover, install the plunger, the cover, back in the valley followed by coil base. 10 mm head bolt (M6?) to fasten ignition coil base, passenger side back, I had the bolt double side taped to a socket with u-joint to start threading. As I am bring the contraption to line up, the bolt drops right above the intake runners. I had all runners plugged with paper towels when I did this the first time. Second time around, with all the frustration of having to do the same again, I over looked closing off the injector housing openings. Now I am not sure whether the bolt went into the intake or dropped in the engine V. Out of frustration I call Jagdpanzer to consult. ‘Course, calm and collected Phil tells me to get a pencil magnet and fish all the IH intakes. I drive out to Advance Auto Parts, buy a couple of magnets on bendable goosenecks. As I am going through each intakes I get to cylinder #3, secondaryintake, I hear that “click” as the magnet gets hold of the missing bolt! Whew!!! Another hour and a half and finally everything is buttoned up. Sure was a day of hell! Hopefully, solenoid rebuild has fixed periodic non-start issue. Last edited by secondchance; 06-26-2017 at 12:30 PM.*