782D starting issue
 

Happy spring all! I'm having an intermittent issue with my 782D and the starter not wanting to turn over. The OEM starter would intermittently turn over at first command of the key switch and other times i would have to give the starter a tap to turn it over. Seeing this as a failing starter I used the opportunity to do the starter upgrade to a gear reduction starter as many have also done. After the new starter was installed all was perfect, turns over when the key is turned and the engine starts almost immediately.

Until last weekend... The intermittent start issue started again. At this point I suspected the key switch, but when looking for voltage at the signal wire to the starter I see voltage is present every time I turn the key. Could it be a ground issue? Looking for advise before I tear into something I don't need to.

Thanks!

It could be the starter. This has been my experience with the chinese starters.

I bought 2 before I came across some NOS OEM's a few years ago. I only use OEM and so far I have not had any problems.

I'm not familiar with how difficult these starters are to remove,
but if easy enough, I would remove and bench test.
(i.e. jumper cables from a known good battery)

Much, much easier to remove than the factory starter. Just two bolts and the main power lead.

Good suggestion on a bench test and I will try that before considering replacement or a new key switch. Its frustrating because its intermittent.

Are you getting 12vdc to the solenoid wire when the key is turned to start? I have one that only gets 6-8vdc and it is not enough to engage it because one of the safety switches is causing a voltage drop. What happens if you take and jump from the battery+ to the solenoid?

My apologies for just now getting back to this... Life has happened and the project was on hold for awhile.

Yes I am getting a full 12v to the solenoid. I've been through the wiring and seem to have good grounds and connections. I am admittedly somewhat skeptical of the key switch but when measuring the 12v lead at the starter it is a constant 12v every time it is engaged. I have also tried a few good batteries I have here at the house, same result every time.

I'm starting to really think its the hi-torque starters from Amazon. I've bought from just about every supplier on there, DB Electrical, etc. I think I'm on #4 now thanks to Amazons generous return policy. When I tap the starter with a dead blow it seems to kick over as if the brushes are sticking. At this point unless someone has a known good source for hi-torque starters I'm going to go back to an OEM thanks to a tip from a fellow forum member. I will say I do really like the hi-torque when it works and how fast the engine starts with it.