starter motor mysteries !

[stockhorse]

F3 Cruiser motor gear reduction starter. working with no sign of problem, starts every time then all of a sudden no start.Not a thing, zip, nada!
Check all fuses, wiring, battery etc all fine. Remove starter and bench test, all test fine. Replace in vehicle nothing! argh!!
recheck all wiring,all fine 11.9 volts to switch wire for magnetic switch but no go.
Any ideas?

[fazza81]

How many starts on test bench?

Denso reduction starters are renound for burning out contacts. Might start every 3 time or so.

[stockhorse]

Hi Fazza, did maybe 15- 20 starts on the bench and it worked every time.I was going to replace the contacts (magnetic switch ones) but they are not pitted or showing any signs of age.I was going to replace the brushes(still well within wear limits) while I had it out but repco can't do them and after ringing 4 auto elecs to be told they can't supply either I gave up and just put it back as is. Toyota want $85 just for the brush plate(comes with brushes) but can't supply brushes separately.

[stockhorse]

All fixed now,similar brushes to falcon starter(falcon are 2mm longer) ford had them in stock.Fitted new brushes and started first try.I must have missed something but I don't know what.

On a side note, got a redarc isolator and all wiring (incuding circuit breakers and fuses)plus anderson plug for charging camper battery, plus second battery tray from the wreckers today.Looks like I will be busy for a few days lol,the whole lot cost me $10.