Todd
I just fixed my intermittent starter today too... actually it was a NEW
(rebuilt) starter that was installed about 3 months ago.  The problem wasn't
solenoid.  So many times I have seen starters replaced only to fail again.
The problem is the trigger wire for the starter - it gets corroded and it
can't carry much current - it does take a bit of current to trigger the
solenoid.

My solution is simple.  I get a 30A relay and use that to trigger the
starter.  The red/black line to the starter goes to terminal 86, terminal 85
goes to ground, 87 goes to the starter solenoid and 30 goes to the
alternator.  I fasten the relay on the front fire wall.

If the starter starts to fail on you - or fails to start - try this - a
simple 10 minute job - 30 minutes on a #^%@#^ Syncro with the fuel tank in
the way!

David Marshall

Fast Forward Automotive Inc.
4356 Quesnel-Hixon Road
Quesnel BC Canada  V2J 6Z3

http://www.fastforward.ca    mailto:sales@fastforward.ca
Phone: (250) 992 7775        FAX: (250) 992 1160

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-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Todd Last
Sent: January 26, 2003 10:36 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Starter not working - problem solved

For those following my previous post regarding an intermittent starter,
I was able to fix the problem.

What I ended up doing was removing the starter, taking the solinoid
apart and cleaning the solenoid. I also polished the solenoid plunger (I
could see some wear marks on it) then put a very light coat of
dielectric grease on it and reassembled it.  I also wire brushed the
starter terminals and lightly sanded them and also applied dielectric
grease on the terminals and reassembled the starter.

Since I've done this, the starter works perfectly.
I don't know how long this fix will work, but the price was right.

Todd
'88 Westy