Start relay

[ken]

My 1994 Bighorn starter relay which is the front one of three black 4cm cube ones on the right side in front of the firewall seems to have packed up. I can hear and feel it operating but nothing happens. Do these unplug or what? My pulling and pushing accomplished nothing. The problem may just be the contacts. Can the cover be removed to adjust the contacts?
Thanks
Ken

[rick1970]

Check to see if there is voltage to the solenoid on the starter when the key is turned. Mine done this, had voltage to solenoid but still would not start.
Removed and striped the starter thinking worn/damaged brushes. Turned out to be worn aluminium housing behind solenoid arm ( where link is that pulls in starter drive) allowing solenoid to travel to far!!
Just built up (re- welded) and replaced bearings, worked fine after that. ;D

[ken]

Thanks Rick for reply
No its not that. I have rigged up a temporary start switch directly to the solenoid via a fuse and it starts every time
Ken

[rick1970]

OK, sounds like the relay is RS. Just replace it with a heavy duty aftermarket type, 40 or better 60 amp rated. Future replacement will then be easier and cheaper

[ken]

Hi Rick
Thats what I assumed. However it did not work out like that. I 'dismantled' the the relay. It is the middle one, not the front one. Mistake no1. The relay was fine. Mistake no2. After much testing and trial and error it appears there is a one ohm resistance in the wire from the relay to the starter solenoid. Have run another wire and it works fine on test. Now all I have to do is 're-assemble' two relays with epoxy.
Assuming can get you into a lot of trouble sometimes!!!
Ken

[ken]

Hi Rick
You might have been right about the worn aluminium housing. Putting a bigger cable in would have allowed a larger current and enabled it to compensate for the wear. I will have to look into this I think.
It is help like this which makes this site so valuable.
Thanks
Ken