Starter Motor Very Hot

[steverrquattro]

Now that the engine is running on the project car (UR quattro with RS2 ADU engine, RR flywheel and WR gearbox), I've noticed that there is a mechanical noise that is coming from in and around the bell housing area. I put my hand on the starter motor and it feels as hot as the exhaust! I can also feel some movement as well, as though the gear is engaged with the flywheel.

So far I have removed the starter motor, greased the shaft and put power to it. However, the gear engages and returns as it should. So I refitted it and I still have the same symptoms.

Any ideas?

[UrS4boy]

A bad ignition switch on a B3/B4 or C4 will leave the starter engaged *AFTER* the engine has started - effectively killing the starter. Not sure if this would be true for an UrQ ignition switch or not.

[martinws]

removing the solenoid wire and checking with meter should show a voltage on cranking then cut out when you stop but I guess faulty switch will keep power on the solenoid, keeping starter engaged.

[steverrquattro]

removing the solenoid wire and checking with meter should show a voltage on cranking then cut out when you stop but I guess faulty switch will keep power on the solenoid, keeping starter engaged.

I measured the voltage when cranking and it was just short of 12V and when the switch was released, it showed 0.8V. I am guessing that this small voltage is enough to keep the starter gear engaged?

[steverrquattro]

Yesterday as a final check, I pulled the lead off from the ignition side (the one that was measuring 0.8 volts) when the car was running and it disengaged. Therefore today I bought a new ignition switch and fitted only to find that I still have the same problem.

Any more ideas?