92 Ex Starter Problem:

[hermitrl]

Hi guys---I had to replace the starter 4 weeks ago around 45 miles back inthe woods while camping. Luckily I had a used spare. It had the usual symptoms---a click but no rolling over. A good whack with a hammer would get it rolling--for a while.
Now this week I was getting the same thing--but a little different. Sometimes I would just get a click--but if I held the key on sometimes it willl roll. hard to describe--sort of a delayed action thing. Other times it will only click unless repeated turning of the key.
I just finished replacing the entire starter again--with a new one. Now--200 bucks poorer it still has that click and nothing else. Hold the key and it will roll sometimes.
Does anyone know what the problem could be? There was a notice about 2 TSBs for the 92 with corrosion on the wire that just connects to the starter terminal--just slides on. I checked that out and it seems to be ok--no sign of corrosion and no voltage drop.
Could it be that relay thingy on the firewall? I don't know what it is called--but have seen people jump the starter with a screwdriver using this relay. Could that be the culprit--and how can I know for sure before spending more cash I don't have? Thanks for your time.

 

[Opera House]

You answered your own question. Just short the two large terminals on the fender solenoid. The solenoid on the starter actually has two coils. One from that spade terminal to ground and the other from the spade terminal to the starter. This provides the boost needed to pull in the plunger that moves the gear out to the flywheel. Consequently, initial current is higher. If there is extra resistance in the fender solenoid or at the solenoid connections, there may not be enough voltage to pull the plunger in and make the starter contact.

 

[hermitrl]

Thanks Opera--I replaced the solenoid just to be sure--and while under the hood noticed what looks like 2 fusible links bolted to the firewall--they were badly rusted and the wire corroded. So I cleaned them off with a wire brush and installed new terminals on the wires. Seems to be good so far---too bad I spent 200 bucks unnecessarily tho.