Clicking, but no starting

I recently replaced the clutch and flywheel on my 92 1.5l Civic LX. It
was running just fine, but now when I turn the key all i hear is a
clicking noise. It sounds like the solenoid is working, but the
starter motor is not turning, any thoughts or corrections.
Thanks
Josh

 

Probably a worn starter solenoid;IIRC,Civic starters have a replaceable
solenoid....without having to replace the entire starter,but if that's not
the case,as was with my 94 Integra,then check out this site;
http://www.nationsautoelectric.com/Nippondenso.html
You can buy replacement solenoid contacts and plunger and "rebuild" the
solenoid yourself at considerable savings.It only cost me $30 USD PPD to do
my starter.The hardest part was getting the lower starter bolt out,in order
to remove the starter assembly for rework.It was frozen into the aluminum
block...the bolt has long threads.Replacing the contacts and plunger was
easy.

The problem is that the contacts inside the solenoid get eroded by the
starter current and eventually do not make contact anymore. You hear the
clicking of the solenoid coil moving the plunger,but the contacts are not
completing the circuit for the motor to get power.

I'm not associated with the abovementioned company,just a satisfied
customer.

 

that's a great link for tegger's honda faq!

 

Checked the battery's state-of-charge?

Cleaned the cables and connections?

Do that first, then condemn more expensive stuff.

 

Yeah, it is. And I'll have to add it.

I'm a bit disappointed Honda is not buying starters from Mitsuba any more.
Now we have the same "contact" failures Toyota owners have had for a
decade.

 

mitsuba? of main relay failure fame? i'm not sure that's a bad decision!

 

Well,$30 for a contact/plunger kit is still better than what you'd pay for
a Mitsuba starter,even rebuilt.
As I said,replacing the contacts was the easiest part of the job.
Knowing it only cost me $30(and some skinned knuckles);priceless! ;-)

 

It's an interesting note that it's happening right after replacing the
flywheel. If you can jump/short the three wires on the starter/solenoid
and it still clicks, not turning over, than it's not the solenoid
contacts. Maybe the starter mounting nuts aren't tight?

Alan

 

I've replaced many Honda starter contacts without replacing the plunger and
never had a come back. There's very little wear on the plunger side of the
contact. Honda used to, and may still sell a replacement starter contact
kit. These included the contact and the plastic bushings. In addition,
just so others know, the contact can usually be replaced with the starter
still in the car (only one of the contacts need to be replaced as the other
does not wear much at all). I've done many and not found a need to remove
it. These were mostly earlier cars up through the '91 Civic. I suppose
that some later models which could have more crowded engine compartments
might be problematic.

Eric

 

I'm a bit confused. Honda has had starter contact problems for years. I
replaced the starter contact on my '78 Accord. Early Civics from the same
vintage, e.g. '76, also used a starter with a replaceable contact.

Eric

 

I agree, I forgot to hook up the ground cable that connects the body with
the tranny on my 97 Civic EX after the same repair. it would click but would
not turn.

Vic

 

On my plunger,there was enough erosion that for $30,it was worth it to
replace the plunger too.The copper ring was bevelled enough that it would
make a poor contact(and would cause erosion quicker on the new
contacts),and since I was already in there....
You could get by with doing just the contacts,but I'd rather do a complete
job.

BOTH of my contacts were eroded ~50%. About HALF the original thickness.
YMMV.