Hi all hopefully someone out there can help as I am banging my head a against a wall!

I have a Rev Mk2 Import G-Ltd and it decided to stop starting a couple of months back, I went through all the usual trouble solving methods and nothing has worked.

I have a battery that is only 1-2 years old and it holds a 12.55 Volt charge, I have replaced the negative terminal clamp to the battery and a new lead to the chassis. I have also just bought a new starter as after many tests I decided that had to be the problem. I did try refurbishing the old one but it failed on certain bench tests.

Now with a good battery, connections, working (& tested) starter motor i'm still getting no crank! I can hear the starter solenoid "popping" or "clicking" away when I turn the key but that's it. I've checked the voltage getting to the starter and its getting the 12.5 volts so in all the guides/advice pages it says the engine may be seized but I have been able to tow start it and I was able to drive it no problem which means the engine cannot be seized!

So any ideas anyone? I also replaced the flywheel with a Fidanza lighter weight flywheel when doing the clutch last year but this has been fine since installed. Could the problem be a seized flywheel? I don't see how it could as the engine runs fine after a tow start.

Many thanks in advance for any help.

I had a similar problem in my case the starter itself didnt bolt tight to the gearbox, one of the threads were damaged and i had to rethread it. make sure both bolts are tight and no big lumps of dirt or old paint is between the starter and gearbox as its a tight fit and cogs must align perfectly otherwise they jam.
Also check all the earths going from engine to chassis mine got oxidized and it didnt help things either.

Yeah I was thinking the earths might be an issue gonna have to start testing them 1 by 1. As to fitting tight its flush up against the mounting hole so no issue there but thanks for the advice.

BUMP

My thinking would be the teeth on the starter are not engaging the teeth on the flywheel correctly. I would take off the inspection cover on the bottom of the box and look at the flywheel for something wrong. You can turn the engine over with a ratchet on the crank pulley bolt, just remember to keep turning it clockwise.

Yeah I was worried bout that i'll have to check it out tomorrow, i'll post here if I make any progress.

Well after a couple of tests on the earth circuits I can now start the car but I have had to run a wire from the starter case to a bolt through the chassis so the earth wires must be the issue as the alternator works but is not charging the battery at the moment. I have the NCT end of the week so gonna get it through that then start replacing the earth wires one by one.

Hey SM0KEY, did you get your starting issue sorted ?

get a dremel with a rough stone on the end and clean the earth wires and where they bolt to down to the shiny metal.

Hi lads no had to go away so not done much, its looking like the earth wires are all shot as running a separate earth wire worked. I'm gonna try sorting it this week and looks like the alternator has given up now

Just an update, so i bought earth wire 35mm and used it to replace the 2 smaller earth wires from the engine to chassis, I also used a machine to clean up the main large earth wire as it looked like crap. Re-installed it all today and fired up first time!

The volt meter on the dash was showing 9ish volts though so I reckon the alternator needs replacing - the joys

Good stuff, i dont think the alternator is the problem, did you clean the earth coming from battery to chassis?
Clean every earth wire you can find and clean the chassis part the cables bolt to.
Is your dash lit up like an xmas tree? if not your alternator is ok.
Also just check the 3 fuses in engine bay.

Cheers for the tips, I also replaced the earth/negative leads from the battery to the chassis so I know they are good and no the dash doesn't light up like that but you might be onto something with the fuses gonna check them today.

Jesus I hope the alternator isn't done in I don't need that at the moment.

Managed to get it all sorted and through the NCT, one of the fuse's had blown the "IG2" fuse in the engine compartment.

Thanks for the help lads