Technical Starter motor issues - Fiat 500F 1970

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Technical Starter motor issues - Fiat 500F 1970

These are my other methods, both will read up to 400 Amps for most starter cranking.
From memory I believe @Pugglt Auld Jock has the bottom one, being old school like me.;)
Still pointless.

A current meter will only advise what current is actually flowing, so if it is low you won't be able to tell which one of the many circuit components is causing the problem.

IMO, the best tool for diagnosing starter cable poor connection/corrosion issues would be a hand held thermal imaging camera, directed along the cable while attempting to turn the engine over. This would immediately show up the location of any hotspots generated by corrosion, or high resistive poor connection.

I'm not saying that the many meters and testers are not handy because they are (I have a tons of them too) but they are only a guide, and can only test a particular aspect, and are not particularly good at fault finding of high current applications.
 
I'm not saying that the many meters and testers are not handy because they are (I have a tons of them too) but they are only a guide, and can only test a particular aspect, and are not particularly good at fault finding of high current applications.
As you say suitable for testing a particular aspect, which in this case I was intending for where a starter motor coils are partly burnt out due to overloading, so they draw a higher amperage than is normal for a good starter.
The thermal test is good for the connections etc.I agree.
I know electricity companies use them for testing along supply pylons, a mate of mine used to hire helicopters to the utility companies and he mentioned when flying them over housing estates how they lit up over drug farms due to high energy use.;););)
 
As has been said before, it sounds like the contact surfaces of the post-clamps need cleaning.
The proof is that the jump-pack to the outside of the clamps makes it work; this bypasses the battery connection.
The lead or brass clamps need bringing to a shine using fine sandpaper or a wire brush, they should ideally have a wipe of some electrical grease or petroleum jelly, and then clamped up, with acharged battery, it should work O.
I’ve briefly cleaned the terminals, but I’ll try again using sandpaper or a wire brush as suggested. Overall, the clamps appear to be in good condition.

I also tested a temporary ground connection from the battery directly to the engine, but it didn’t make any difference.

What puzzles me is why this would suddenly become an issue, especially since everything worked fine before the ignition failure.


Could there be another explanation?
 
Could there be another explanation?

Nope, not from what you've said/how you've described it.

You specifically said:

When I pull the starter using a fully charged battery, it sometimes cranks very slightly, but that’s all. It cannot start the engine.
However, when I use my jump starter (which delivers up to 800A), the starter cranks and engine starts perfectly.

I'll repeat: If everything else you're doing to start the car is the same (battery alone or booster pack), and you're clamping the booster on top of/over BOTH battery clamps then the only thing that makes sense there is poor condition battery posts and/or clamps. (or the battery itself)

You're attaching the booster 12V to the exact same point in the car circuit as the battery , but you're attaching the booster to the outside of the clamps , the battery connects obviously to the inside of that same clamp.
 
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My instincts still point towards the starter being partly burnt out due to "flogging " it over when you had the ignition problem which you mention was the start ? of the starter problem. It is something I have seen before and yes I agree a big battery or power pack will kick it over faster, but I feel that may be disguising the problem.
Even on this Forum I have read posts on slow turning 2.8 Sofim engines in Motor Homes that a new starter has made a massive improvement.
Also bear in mind the vehicles are many years old, so a good chance the starter is too.:)
 
Both above theories have their own merit. Testing the battery connections is the simplest to do, so: Take a voltmeter (multimeter) and place the probes on the outside of the battery terminals and see what the voltage is when cranking, then repeat with probes on the actual lead terminals of the battery itself. If the voltage is lower when the probes are on the outside of the terminals then the connection between the terminals and battery post/s are the problem

@ZaphodB I've wanted a thermal imaging camera for a while now - Lots of posts on you tube about what interesting things you can do with them - but i really can't justify the cost - I'm talking about a "proper" imaging camera here, not just a temperature gauge.
 
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Have we any pics of the clamps ?

Is it a tapered post battery

Are they cast or strip metal?

cast.jpeg
strip.jpeg

I'm wondering if they've been stretched over the years offering little clamping force ...
When attached is there still a gap where the bolt is?


A good test I've used in the past for revealing a knackered clamp (depending on the design) on someone elses car is to grab a firm hold and try and twist it off the post (use a rag if your skin is delicate:D)

You could also try removing both clamps and attaching jump leads between clamp and post
 
Have we any pics of the clamps ?

Is it a tapered post battery

Are they cast or strip metal?

View attachment 470055View attachment 470056
I'm wondering if they've been stretched over the years offering little clamping force ...
When attached is there still a gap where the bolt is?


A good test I've used in the past for revealing a knackered clamp (depending on the design) on someone elses car is to grab a firm hold and try and twist it off the post (use a rag if your skin is delicate:D)

You could also try removing both clamps and attaching jump leads between clamp and post
Might be that the actual wires in the lead are not making a good contact with the clamp? I've seen this particularly with the type you show on the left where the wires can come loose under the little retaining screws?
 
I’ve briefly cleaned the terminals, but I’ll try again using sandpaper or a wire brush as suggested. Overall, the clamps appear to be in good condition.

I also tested a temporary ground connection from the battery directly to the engine, but it didn’t make any difference.

What puzzles me is why this would suddenly become an issue, especially since everything worked fine before the ignition failure.


Could there be another explanation?
My last two battery failures showed 12.6 volts at rest but were completely dead. I dont trust new batteries either till they prove themselves and settle down!
 
... I also tested a temporary ground connection from the battery directly to the engine, but it didn’t make any difference...
I hope you were wise enough to check this at several points on the engine (even on the starter motor itself) remember you're only trying to prove a point. Once you prove it, you can fix it, untill then you're still guessing exploring.
 
@ZaphodB Whilst I agree with every point you make in your post #31, I also think there is some mileage in @bugsymike's post #32

However, properly testing the earth path, can rule it out at almost no cost.

Yep I don't disagree, it's got conflicts this story from the described symptoms and actions so far

I hope he comes back soon, I'm gonna be on my death bed "did we find out ?...." 🤔🫣
 
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