KZJ78 not your typical starting issues

[Miles8503]

Got my KZJ78 about 4 months ago, love it still finding excuses to drive it everywhere. Bone stock except for a aftermarket radio and some seat covers.


But having an odd starting issues lately intermittent for the last month or so but really bad the last couple weeks.

After a short drive when it's 80-90+ degrees outside it will not start. No constant click, such as when the battery is low, no noise. I can hear the glow plug click but turning the key all the way it will make absolutely no noise. After cooling down 30-45min+ it will start up fine. I've dumped a bit of water on the starter itself and the relay to cool it down faster and that seems to do the trick if I'm stuck somewhere.

Replaced the starter relay today and tightened all the battery connections, thinking that may have been the issue. Didn't work, luckily I turned it off in my driveway so just went inside.

Any thoughts? Thanks in advance.

 

[AirheadNut]

Sounds like the contacts in the starter solenoid are worn and need to be cleaned and the solenoid plunger greased.

Here are some photos of an HDJ81 starter I did a number of years ago; yours should be pretty much the same inside.

 

[Miles8503]

Sounds like the contacts in the starter solenoid are worn and need to be cleaned and the solenoid plunger greased.

Thanks appreciate it, that was my next course of action. When I was researching it, seemed like something other than the starter solenoid due to other posts and symptoms. But I will try that out.

 

[Tigris]

X2 the starter brushes/plunger contacts... Had similar symptoms years ago on an fzj80 and that was the correct diagnosis then.

Btw, do we know of a source for a complete OEM starter rebuild kit for the KZJ78? I would love to rebuild mine recreationally.

Cheers!

 

[Miles8503]

X2 the starter brushes/plunger contacts... Had similar symptoms years ago on an fzj80 and that was the correct diagnosis then.

Btw, do we know of a source for a complete OEM starter rebuild kit for the KZJ78? I would love to rebuild mine recreationally.

Cheers!

Thanks appreciate it. Through my limited search, I will probably go with Roughtrax kit to save on shipping the parts individually from megazip or other places.

 

[Miles8503]

Had some free time today so took out the starter. Wasn't particularly difficult came out much easier through the wheel well than I thought it would. Glad I knew in advance where the second bolt high up was.

While I wait for my repair kit I will clean it all up, try to get the corrosion off the plunger and contacts and see how it works. Thanks for the advice from all, much appreciated.

 

[Miles8503]

So cleaned it all up, plunger, contacts, everything I could. Replaced starter, fired right up as usual no issues, tested it a couple times cold all good. Took it on a little drive, its hot today 95+ so figured would be a good test. Did the usual route, came home parked it and nothing. No click when I turn the key, everything dims like it's trying to send power somewhere but starter doesn't even try to start.

Thinking and might be wishful thinking that the contacts where the plunger hits were worn slightly uneven and had a decent groove to one of them but less of one on the other and that maybe the issue once replaced fully.

In the mean time as I wait for replacements, any other thoughts or suggestions to trouble shoot would be appreciated.

 

[AirheadNut]

Did you grease the plunger as per the manual? If so I’d just start going through the cables leading to the starter and clean and check every connection.

 

[Miles8503]

I did not, mainly because I had some free time so wasn't super prepared but I will grab some and next time I pull it, I will grease the plunger. I will start going through the cables, thanks!