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Starter Run-on Fixed

Starter Run-on Fixed

BJ Kroppe

Hunt Dabney was right - it was the solenoid sticking.

Here is a summary:

Vehicle: 1982 SIII XJ6, fuel injected, USA market

Problem: Starter motor continues to crank the engine even after the key is removed from the ignition. Battery must be disconnected to stop the starter.

Cause: In this case it was dirty high-current contacts in the starter solenoid, causing the contacts to be welded together under the high current. This prevented the solenoid from disengaging, causing the starter to run on.

Solution:

  • Remove the starter motor.
  • Remove the solenoid from the starter motor.
  • Remove two cross head (philips) srews from top of solenoid.
  • De-solder in two places to allow cap of solenoid to be removed.
  • Be prepared for a few parts to fall out of the solenoid and avoid letting the solenoid "bullet" drop on your toe, it's heavy enough to hurt (I know).
  • Note the location of the two copper studs and contactor plate.
  • Polish the mating surfaces of the copper contactor plate and copper studs. Re adjust the position of the small ignition contact finger. I used crocus cloth. (Very fine emery cloth, red in color).
  • Reassembly is the reverse of removal. Take care to re-solder in two places. Also do not smear the grease around on the copper bullet. My gut feeling (but I'm a mechanical engineer, so what do I know?) is that too much grease would affect conductivity. But you do need some grease to prevent binding.

Verification: IT WORKS!

B.J. Kroppe - '82 XJ6

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