A.J. Matthews, #605, Ay Mon
Find a good automotive-electric
repair shop. The kind that specializes in alternators and starters. make
sure the firm "marinizes" their work and you are set. I have a few of these
shops down here in Florida.
Heck, if you cant
find a shop where you live, the shipping costs would be worth it to avoid
the $715 bite!
I had my alternator
rebuilt and upgraded for a measley $75.00. It went from having an alternator
that wasn't putting out squat to an robust 70 amps. Compare that to a new
unit that went from $395-800.
Skip Baker, #3, White Cap
I was chatting with
the local BMW (boat maintenance worker) and he had a comment about my little
Westys' poor cold weather starting capability. He suggested having
a battery company make me a starter cable out of #1 gauge cable.
He remarked that most battery to starter cables were made for perfect conditions.
Factors like cold weather and the eventual cable corrosion that sets in
can limit the available amperage to the starter to the point that it cannot
spin fast enough to start a diesel.
I would imagine
that the reduced power would also put a much larger strain on the starter
and negatively effect starter life. He had stated that by doing this
on several Catalina models he had fixed problems that starter rebuilds,
larger battery installations, etc. had failed to fix.
Ray Alsup, #256, Pegasus
Sounds like a bad
throw out bearing (I think that's what they call it.) I have never
taken an A4 starter apart but technically it must be the same as an automobile
starter and there are replacement parts in them. Its rare that a
starter has to be rewound. If you do not feel comfortable taking it apart
yourself, find a local starter repair shop and have them test it and tell
you what's wrong before spending megabucks to replace it.
There are also
a lot used A4 parts around the boating community. If the your starter must
be replaced, check around the local boat yards or talk to other A4 owners
in the area or here on the listing for some leads. A used starter
was probably running just fine until someone decided to scrap the engine.
Mickey, #644 (formerly Kulshan) Victoria BC
You've gotten some good advice on how to deal with the starter and beef
up the battery cables. However, since you say the starter does work but
only at one position, this suggests that the problem is the relationship
between the starter gear and the flywheel gear, rather than the starter
itself.
You did say the teeth on both look good, but you may want to double check.
Be sure you are looking at the Flywheel gear teeth from the side the starter
engages them - not the easy-to-see side, front of the engine.
Typically what happens in IC engines in general is that they stop with
the gears in only certain positions, due to compression and piston location.
This means that each time the engine was started over the past fourty years,
the gears experienced wear in only those few positions. The gears may now
be so worn that you must persuade the engine to some other rotational angle
(between the wear spots) before there's enough bite between the gears to
get it spinning. Once it starts to spin the total load on the gear teeth
is less, so even tho' they're worn and noisy the engine will usually spin
enough to start. Usually it is the ring gear on the flywheel that wears
the most, not the starter gear.
If worn teeth are the problem, replacement of the gear(s) is in order.
My Atomic 4 Parts Manual does not list a flywheel ring gear as a separate
part, so it may be that the gear teeth are machined directly on the flywheel
(but I doubt it, this is not usual for other engines - also, it refers
to the "flywheel assembly"). This may be academic, since you're more likely
to fine a used flywheel than a new ring gear anyway. If it turns out that
this is what's wrong, and you do come up with a ring gear to fit on
your flywheel, sing
out and I'll describe the procedure for replacing it, using only equipment
you already have in your own kitchen.
Bob, #140, Akasha
The fly wheel is one big solid piece of iron, easy to remove, or just take
it off and rotate it and reinstall it so that the point that it seems to
want to stop in will be a new place on the wheel. Good luck.