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Old 04-28-2013, 05:11 PM   #1 (permalink)
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Default Starter solenoid problem

My '87 Samurai has the clicky starter problem for the first time today. Luckily, I was home when I experienced the problem. After reading thru some of the posts on the subject, It's my understanding that by installing a relay on the ignition switch control line to the starter solenoid and allowing a direct fused battery link
to activate the solenoid switch will solve the problem. If if wrong, please correct me. Thanks, Lee
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Old 04-28-2013, 05:49 PM   #2 (permalink)
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Here is a good diagram on what is needed.

Suzuki Samurai clicky starter relay upgrade

Using the lesson learned with this fix, here is a diagram for the headlight wiring harness upgrade using relays.

http://civilianjeep.info/Strenk/Ligh...sswithplug.JPG

Last edited by Haptown; 04-28-2013 at 06:06 PM.
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Old 04-28-2013, 07:31 PM   #3 (permalink)
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Thanks for the info. The diagram is constant with what I assumed. Curiously, I'm wondering why the ignition wire all of a sudden cannot activate the solenoid switch. I measured 12v on the activation line, but did not check the current. I'm guessing that the deterioration might be in the solenoid itself and not the connecting activation line. A direct battery connection apparently can fix that circumstance though.
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Old 04-28-2013, 09:00 PM   #4 (permalink)
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Probably a combination of the wires being to small, corrosion in the ignition switch, and poor grounds. The result it that there is not enough amperage being passed to engage the solenoid.

Might also be a good time to check the battery ground. Besides the main ground cable going from the battery to the engine block, make sure you also have a good ground to the body. I run a 4-6 gauge lug cable from the block and bolt it to the firewall. Just don't trust the small wire from the battery ground terminal to the firewall connected with a small screw.
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Old 04-30-2013, 02:02 AM   #5 (permalink)
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Quote:
Originally Posted by Haptown View Post
I run a 4-6 gauge lug cable from the block and bolt it to the firewall. Just don't trust the small wire from the battery ground terminal to the firewall connected with a small screw.
I like that Idea.... Gotta Do It.
Grounds are so Important
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Old 04-30-2013, 06:56 AM   #6 (permalink)
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Please be aware, the "clicky starter" fix only addresses one of several possible causes of a clicking starter - you really should troubleshoot the problem.
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Old 04-30-2013, 10:41 AM   #7 (permalink)
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Now i don't have any problems (knock wood) with my starter but if it did the clicky thing you would think you can get in at the starter solenoid with a short screwdriver and start it that way. At least that's how i started them back in the 70's with cars that didn't have locked steering column and i had no key. A simple jumper wire from the positive side of the coil to the positive side of the battery turned the key "On" and the screwdriver got the starter to spin.
Maybe these zuks are different but they sure look the same as the old ones i did
Joe

Last edited by Joe Z; 04-30-2013 at 10:44 AM.
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Old 05-03-2013, 05:59 PM   #8 (permalink)
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My clicky starter problem briefly went away after I repaired a loose connection of the ignition switch wire to the battery. However, the clicky problem reappeared and left me stranded at the post office parking lot. I walked to an auto parts store and bought a 30 amp 5 pin relay (only needed 4), extra 14 ga wire, connectors, etc and rigged the whole mess up in the parking lot just to get me home. However, the clicking was still there. When I push started it, the starter hung - had to have it towed to a shop and a new starter fixed the problem. I'll reinstall the relay setup properly now to prevent future problems.
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