Main loom.

[SteveD]

Home from work now. 2300hrs here.

Since you have the starter cover off, try testing the starter by using a screwdriver to short across the positive terminal (big wire from battery) to the other connector with a black wire on the solenoid. This bypasses the relay, switch, wonky wiring, etc.

That was the method I used on my MG Le Mans when it wouldn't start, which was whenever it got hot.
It worked well then, but this time all I got was sparks and clacking.

checking the contact pins that mate with the offending multiplug

Whilst I was talking to Airbear yesterday, I did remember how I cleaned those pins...with a light use of a dremel type tool. I might've just diminished their critical width?? Inside, it all looks fine. Wriggling the loom just where it enters the multiplug can cause the lights to come on or off. So the problem is either a wire issue in there ( I'm now doubting that, and thinking the pins may not be tight enough in there?

Thanks for the replies.

The issue of the clacking persists, despite jumping and also shorting the starter. That's now my main concern.
Why would it not start via the shorting method? Does this mean the solenoid is the likely culprit? What to look at next. This is wilderness territory for me, so I'm appreciating the help.

The solenoid has "espana" on it. I'm guessing Bosch didn't make theirs there, so this is a Valeo?

[Airbear]

Morning, Steve. Can't help with identifying the starter, but here are some links ...

Valeo starter overhaul http://www.largiader.com/tech/valeo/

Bosch and Valeo info from Snowbum http://bmwmotorcycletech.info/boschvaleostarter.htm

Snowbum notes that your model uses the 9 tooth starter, so scrounging an earlier model will not work.
He also notes that the solenoid for the Bosch is the same as for early VWs. Perhaps the solenoid on yours was replaced with a spanish clone (?). He includes info on cleaning the solenoid internal contacts (possibly the problem with yours) but you need a big soldering iron to disassemble it.

An article referenced by Snowbum on rebuilding the Bosch
http://www.thisoldtractor.com/gtbender/ ... _starters-

Any auto electrical workshop should be able to get whatever bits are required and do a rebuild. I know you are running low on time for the weekend run, so perhaps sending it out will be a good option.

ps: I'm pretty sure the Bosch starter on mine has 'Bosch' in big confidence inspiring letters stamped on the side. It doesn't take much to remove it.

[ME 109]

I'm thinking the 'clacking' is evidence that the solonoid is working at there is not enough power to drive the starter motor.
Hooking up jumper leads will not help if the power wire to the starter is suspect.
Maybe need to hook jumper cable directly to stater + to be sure.
It is odd for so many failures to exist at one time.

[SteveD]

Thanks Jeff.

Some advice from a mechanic friend...rides a Guzzi and has years of Norton experience.

What you want to try is crossing the small wire(feed from starter button)with the large cable that comes from the battery.If battery is charged and terminals are tight this should activate solenoid engage starter pinion and make engine go.Crossing the two big terminals will create sparks make starter turn but will not engage starter pinion to turn engine.Check for power supply to small wire with ignition on and press starter button.

The small black wire has power when tested.

Maybe need to hook jumper cable directly to starter + to be sure.

Jumper positive direct to large starter positive , negative to frame? If it works, proves the battery kaput?

[SteveD]

Thanks Jeff.
Jumper positive direct to large starter positive , negative to frame? If it works, proves the battery kaput?

OK. Didn't work.
Headlight remains strong and han't lost any brightness with all this fiddling about.

I'm guessing this means a new starter/solenoid will be required.

[ME 109]

Jumper positive direct to large starter positive , negative to frame? If it works, proves the battery kaput?

It would prove a problem in the power cable to the starter, or, prove that the initial loom problem is affecting the starter. or, prove the battery is flat, or prove that the solonoid IS caput.
Provided the starter is earthed ok, and the battery earth is good and tight, you should only need the one cable to starter +

Clacking is poor battery or poor connection........ usually.

Hope a miracle happens man!

[SteveD]

Jumper positive direct to large starter positive , negative to frame? If it works, proves the battery kaput?

It would prove a problem in the power cable to the starter, or, prove that the initial loom problem is affecting the starter. or, prove the battery is flat, or prove that the solonoid IS caput.
Provided the starter is earthed ok, and the battery earth is good and tight, you should only need the one cable to starter +

Clacking is poor battery or poor connection........ usually.

Hope a miracle happens man!

Thanks Jeff. With this testing tonight, there wasn't any clacking, just a low squeal. RG has a starter, I'm about to go collect it.

[grant81rs]

Have a safe drive down there mate, bit of a haul at this hour of the night after working a long shift all day.....

[ME 109]

???

[Bob Bennett]

Yeah,,,,,,Wots happened??/

Hey Steve, I think the problem with your starter is the solenoid,
Looked at the UK forum and saw Rob's ideas and had my own thoughts so
posted them there.

Regards Bob,