Starter motor

[ken]

Hi Fellers.
I hope someone out there can help me with my starter motor problem. It started a long time ago with the starter not working occasionally. I put a bigger wire from the relay to the solenoid and this fixed it for a while but then returned. Thinking it might have been one of the safety interlocks I put a bypass switch directly to the solenoid as a test but this did not fix it.
One of the members said he had had this problem and it was due to wear on the housing allowing the solenoid to sit too far out from the coil. I took it to bits but there was no wear on it. On putting it back together it seems that the starter does not switch off. I eventually got another starter from trade-me thinking my troubles would be over. Not so.
I had the engine running for a while and smoke started coming from the starter. On Switching off, the solenoid was very hot.
I rigged up a test lamp and found that both solenoid and the motor terminals were alive with the engine running (both old and new starters). On disconnecting the battery supply at the starter and operating the key start there was voltage at the solenoid and motor terminals in the start position but nothing at the run position ( as you would expect)
I can think of nothing else to try.
Any ideas would be appreciated
Ken

[geeves]

First thought would be a short in the solinoid but normaly people selling starters sell the solinoid as part of the package. There is a relay in the fuse box that operates the solinoid that could be sticking. Otherwise its a trip to auto sparky

[ken]

Thanks Geeves.
Is there anywhere I can see a circuit diagram preferably a schematic?
Ken

[ken]

I have found that using a starting switch directly from the battery (through a fuse) everything works fine. With the normal wiring disconnected at the solenoid the relay seems to operate OK using a test lamp. The light goes out when going from start to run position. Bit of a mystery.
Ken

[geeves]

Have just sent some diagrames from an 87 trooper that should help to your .clear address
These shouldnt of changed much on the later models.
If no help There is a complete 97 manual in the gmail account but its 100 meg to download

[ken]

Thanks for the help Geeves
Ken