At 04:20 PM 2/15/2014, David wrote:
>I emphasize that this happens infrequently, and when it does, the period of
>time before the starter kicks in is usually almost imperceptible, but it's
>enough of a delay that you're aware of it happening. There does not appear
>to be a correlation between outside air temp or whether the engine is warm
>or cold.

I guess it's possible that this could be from the ignition switch
(and you ought to carry a spare regardless, as it's a trivial matter
to temporarily substitute in for testing or until you can install it
properly into the lock assembly).  You can eliminate the ignition
switch and all the control wiring if it doesn't operate any better
when you connect a mechanic's remote starter switch directly from the
alternator B+ terminal to the starter control terminal.

However I'd be surprised if this weren't the result of the starter
solenoid internals getting sticky.  The next time it's balky either
get someone else to turn the key or use your remote starter
switch.  Either way, rap the side of the starter with a hammer while
the key is turned to start or the switch is pressed.  If the starter
operates at that point you've found the problem.

People have successfully taken these starters apart and cleaned them
up inside.  I haven't done it so can't help with details.  The
alternative of course is a rebuilt starter.

There is one unlikely possibility:  It can happen that the control
wire works off the terminal on the starter and hangs there just
barely (or sometimes not quite) touching the terminal.  I've had it
happen in a Vanagon and a Fiat 128, so I know it's possible.

Yours,
David