i was getting ready to do a water pump, pulley, and timing belt change on my neon today, i was going to move it to the drive way and off the street to do this.... only it will not start. i hear the selnoid clicking and the battery is charged. i took off the starter and bench tested the unit, it kicked on without a problem. to make sure nothing seized on the engine, i turned the crankshaft pulley a bit (with the timing belt still on) and it moved without a problem... yet the starter cant move it. i noticed the selnoid was rather hot for just the few seconds it was engaged, and i bet thats where most of the problem lies. i have been trying to find a rebuild kit for the starter, but have been unable to locate one. does anything know if they have a rebuild for neon starters?

 

i decided to wing it and do a rebuild without a kit, got the unit tore down, cleaned it all up, cleaned the brush surfaces and contacts, (two of the brushes werent even in the sping holders). i didnt tear apart the selnoid, though i will probably do that soon. i am going to hook the starter up to the neon and see if it moves the flywheel now.

 

welp, looks like the rebuild was successful. it kicks hard now and appears to be doing great. i do have some advice to anyone who attempts this, when you put the brushes back in the spring loaded holders.... put one brush in a holder and attach it to the bracket... put the spindle in the center, and then do the brush directly across from it. put that one in the holder with the spring, push it up against the spindle, and while pushing it down to the bracket rock the spindle back and forth allowing it to go in.

 

glad to hear it was a success, did you get to polish the commutator? did the brushes looke like they were in good shape?

 

I've done this, mine had a buch of sludge in it.