defender 90 200tdi starter motor problems

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kidoletatu

kidoletatu

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Hi all, I am new to this forum and first time posting a problem, although I use it frequently to solve issues with my defender on a regular basis.

Not long ago, I burnt out a starter motor and I think the cause was that the key turned over too far which meant the rod from starter did not retract. I have replaced it with a second hand motor and it started fine although there was a slight crunching sound for a second, which didn't fill me with much confidence. I have since driven it around for about 15 miles. I went to start it again the other day and it didn't start first time, sounding like the starter had gone again. Is it possible that there is a faulty ignition switch, that is causing the problem for these starter motors to burn out?

I have removed what I think is the starter motor solenoid wire from back of ignition switch (see photo) and there is still charge to solenoid terminal.

what should the charge be with wire out?

Thanks.
 

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Wire in or out should be zero. Only 12v when key in right position. Have a look at wire full length, it might be burned into battery wire to starter.
 
Thanks will have a look. on the solenoid, do I measure voltage from terminal of ignition wire or terminal where battery cable and alternator attach to?
 
Battery cable to starter will be 12v always, everything feeds from thick starter cable. Little wire is not live until you work key. It will be zero volts and 12v when you turn key to starter position. This is my 85 90 system with 200tdi.
 
I would take a good look at the ignition switch first and if not sure its okay just replace it.
 
Thanks guys! It is a year 93/94. I might just get a switch as they are not expensive. I won't need to replace the whole starter cylinder I presume, just the switch at the end?
 
I would change the lot as you will most likely find the barrel return spring is built into the barrel and not the electrical bit.
 
It looks like those wires have been repaired/replaced, perhaps there is a long-standing issue. Don't forget there is also a starter relay on the rear of the fuse box that could cause problems.
 
I think on my 200 its straight from the ign barrel to the starter motor, big fat white wire with a tracer Iirc?
 
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