You might want to check the small cable that goes from the solenoid to the
starter motor itself.  This is a short and very thick
cable.....................see my response to a similar previous inquiry by
another member.  See item:  167092 dated 01/11/22  re:starter problems in
the archives.  Good luck.  Claudio Cella
----- Original Message -----
From: "mike miller" <mwmiller@CWNET.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, December 04, 2001 9:29 AM
Subject: Re: 82 with hot start problem (long saga)

> Bad ground cable or hot cable from the battery to the starter?
>
> Mike
>
> > From: Laura Olson <laura@ONEOTA.NET>
> > Reply-To: Laura Olson <laura@ONEOTA.NET>
> > Date: Tue, 4 Dec 2001 09:53:01 -0600
> > To: vanagon@GERRY.VANAGON.COM
> > Subject: 82 with hot start problem (long saga)
> >
> > I would guess this subject has been covered sometime, but I flit on and
off
> > the list as my life allows.  This past August, I took a trip from NE
Iowa
> > to Glacier National Park with three young boys and the family dog in my
> > 1982 air cooled Westy.  Before I left I had a whole new exhaust system
> > installed and purchased a new battery, even though my old one was
probably
> > fine.  I bought the battery because I had had some strange starting
> > problems three previous times in the Spring and Summer-had a new starter
in
> > 2000.  The battery did not solve the problem.  As soon as I was 5 hours
> > away and stopped for a picnic lunch at a rest stop, the van would not
> > start.  The three previous times this had happened, it started right up
> > with a jump.  This tow truck driver tried his battery charger and it
didn't
> > go, so towed me to an import repair shop in Sioux Falls, where we had to
> > spend the night as they couldn't possibly look at it until morning.  Oh,
> > joy.  Of course, it started right up in the morning and I let him put in
a
> > new ignition switch in case that was burning out.  He lent me a battery
to
> > jump from and off we went.  This time, we made it as far as Wall, SD (it
> > started after the first two stops for gas) and it wouldn't start.  We
> > wandered through Wall Drug for two hours hoping it would cool down
enough
> > to start.  No dice-so I got a guy to jump it who sent me to a place in
> > Rapid City with German mechanics.  The next day, they fixed it!!!  They
> > checked the drop voltage on everything and replaced the voltage
regulator.
> > I was wary and didn't turn it off that day until parked for the night in
a
> > state park outside Thermopolis, WY.  I tried to start it again and it
> > worked!  I was overjoyed.  For the next 10 days, the Vanagon was once
again
> > in my sons' good graces and we drove all over Wyoming and Montana
without
> > fear of turning it off for gas or hikes or lunch.  It was always in the
> > 90's on this trip.   Feeling somewhat cocky, we started home and it
started
> > happening again, not far from Billings, Montana.   I had to have it
jumped
> > at a gas station, but not in the morning after setting all night.  The
next
> > morning, I thought a short drive (1 hour) to the Little Bighorn
Battlefield
> > would not cause a problem, but it wouldn't start there either (probably
our
> > hottest day).  The bikers returning from the Sturgis rally were helpful.
> > Anyway, I was determined to get back to Import Services in Rapid City.
I
> > drove without turning it off until the Black Hills, where we spent two
> > nights waiting for Monday morning.  Took it in Monday morning and they
said
> > they couldn't look at it until Wednesday so I said screw it, and drove
> > home.  I didn't turn it off until I was parked for the night.  Except I
> > stopped at the first repair shop in Sioux Falls so I could drop off the
> > battery he had loaned me, and I had three guys out there stumped. They
> > tried to start it and checked the voltage on the battery (12 something),
> > then tried to jump it with a charger pack (12 something, a little
higher),
> > then jumped it with a car and cables and it started with 13 something.
It
> > has started faithfully since but I haven't driven it for more than an
hour
> > at a time.  My mechanics here in town are confused; of course it never
> > happens in town where they can observe it.  Any ideas on whether this is
> > fixable.  It is frustrating because I bought the Westy for long trips-I
> > live to drive around the country-but am planning our Spring trip to
Phoenix
> > and summer trip to Seattle in our trusty Honda wagon with a tent
strapped
> > to the top. Help.  Thanks,  Laura
> >