Join Date: Jan 2013
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Re: Yanmar 2GM starting issue (sort of)
After verifying Battery + cable to solenoid and Ground - cables are clean and secure (as described above) first replacement to try is starter solenoid. "Clicking" indicates solenoid is energizing properly, but not making the required high current connection between battery and starter motor. Cheap, (~30.00) and it fits symptom of intermittent problem.
Contact surface inside is usually a thin metallic disc which contacts the lg copper studs when solenoid is energized. Disk rotates at random helping to distribute erosion caused by high (60-100A) current arcs when contacts open and close. After sufficient wear, disc will be too eroded to make adequate contact in all positions. Repeated engagement of solenoid "joggles" the disk around till eventually you reach a position where the disk will make contact with both studs. Depending on the solenoid type and mfg it is sometimes possible (not recommended) to disassemble the solenoid file the terminal posts and disk to get a faulty solenoid working in a pinch.
When I purchase a solenoid, I am fine with a 'Rebuilt". New terminals and contactors are basically replacing all the parts that wear. Your mileage (or opinion) may vary... While it is possible to replace the solenoid without removing the starter (depending on your engine space), probably best to pull the starter out. While it's out, go ahead and check the brushes, and the bendix for damage/wear. Hey, its already out.. right?
"If the wind will not serve, lay to the oars"
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Last edited by Cap-Couillon; 10-08-2013 at 11:05 AM.