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the_mad_electrician · Joined: 16 Nov 2009 Posts: 1073 Location: Central Georgia

trying to run down the electrical issue with the starter is proving to be more difficult than I thought. The starter works fine with a fresh battery and its still cold but if I don't get it fired with in seconds it starts acting crazy and wires that don't seem to have anything to do with the started start to smoke. I have the Haynes manual but the wiring diagram doesn't help much when half the wires have mulitple splices and the other half have color so fade I can't tell what the hell they are. This is a nightmare! Just when I got the car running again. I'm ready to drive! Someone as impatient as me should never by a project car!

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81 924 N/A

2004 Ranger "Edge"

2005 Mazda 6

9XX Girl! · Posted: Thu Jun 24, 2010 4:14 pm Post subject:

Check your ignition switch (if i remember correctly), when cranking, the ignition switch should turn off all circuits except for the fuel pump and ignition amplifier.

The starter is obviously causing lots of volt drop so if other circuits are running while cranking, given their resistive value, as the vehicle's voltage drops, the current in those "still on" circuits goes up (to the extent that it exceeds the tabulated current carrying capacity for the given cross sectional area of the wires).

Also check starter connections. make sure only the solenoid is pulling current from the ignition circuit and not the starter motor its self.
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924 (84) N/A 2 ltr - 5 Speed - BLACK - Project (looking for 200BHP, any ideas!)
924 (81) N/A 2 ltr - 3 Speed Auto - SURINAM RED (Metallic) - Near Original Spec (sticking with originality)
BOTH ON THE ROAD, BOTH USED EVERY-OTHER DAY

DOCO · Posted: Thu Jun 24, 2010 10:42 pm Post subject:

sounds to me that you have a bad ground,and when trying to start it,the grnd will take the least path or resistance,to make connection.thus small grnd wires ,to much amprage,smoking wires.check the main negative lead and bateray,but mostly at where it connects to the block.its such a bad connection there,that is usually the spot.i made a new cable from batery to block with normal battery cable.sttarts and turne over no problem.easy wat to check take a jumper cable and conect to neg battery post,connecty other end to starter HOUSING and crank it over,see if this works.by the by ground can be considerd earth.
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Doco "where am i going and why am i in this handbasket"author unknown
79 924 N/A "Webster"
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/______\
[+]___[+]
\0 924 0/
[__]..[__]
"WEBB STR"

DOCO · Posted: Thu Jun 24, 2010 10:45 pm Post subject:

oh and is this all just happened after the webber install?you may have forgot the conector at the top of intake.thats the main ground and it is some poor ass workman ship.small connector no good with big amps.running through it!!!
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Doco "where am i going and why am i in this handbasket"author unknown
79 924 N/A "Webster"
_______
/______\
[+]___[+]
\0 924 0/
[__]..[__]
"WEBB STR"

Smoothie · Posted: Fri Jun 25, 2010 1:16 am Post subject:

+1^, +> the starter is grounded through the large bolts that hold it on, and the metal surfaces between it and the block or bellhousing (depending on model). -So every once in a long while it's good to chase those large mounting bolt threads with a tap and die.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

the_mad_electrician · Joined: 16 Nov 2009 Posts: 1073 Location: Central Georgia

Slam · Posted: Sat Jun 26, 2010 1:09 am Post subject:

You may also want to check the ground between the alternator and the body. Like the main engine ground, it's kinda rinky-dink and a source of problems.
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'88 944 Auto - may or may not resurrect

the_mad_electrician · Joined: 16 Nov 2009 Posts: 1073 Location: Central Georgia

its probably a bad thing when there's over 2.4 ohms of resistance between the engine and the body of the car. the bolt that holds the ground strap to the body won't even read continuity to the engine... that might be my problem.
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81 924 N/A

2004 Ranger "Edge"

2005 Mazda 6

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

Yeah.....

(swigs beer)

BURP!

it might....

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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

9XX Girl! · Posted: Sat Jun 26, 2010 9:34 am Post subject:

fiat22turbo · Joined: 18 Jan 2006 Posts: 4040 Location: Portland, OR

9XX Girl! · Posted: Sat Jun 26, 2010 10:25 am Post subject:

Joes924Racer · Posted: Sat Jun 26, 2010 10:44 am Post subject:

the_mad_electrician · Joined: 16 Nov 2009 Posts: 1073 Location: Central Georgia

I found that it was not only wries smoking but the starter itsself! this sucks!
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81 924 N/A

2004 Ranger "Edge"

2005 Mazda 6

Joes924Racer · Posted: Sun Jun 27, 2010 7:22 am Post subject:

The wiring from the battery to the starter and alt have issues with the heat you might have to make a new harness there.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.