Quick starter motor connection question. 2.5 TD

[Tony x]

Hello,
Can't find the answer to this question so I'm hoping for help.

I'm replacing a heavy duty starter from the north Japan model Bongo with the standard one.

The heavy duty starter has 2 copper coloured connection studs which connect to the electrics using nuts on the studs. It also has a small clip on connector

The replacement starter has only one stud although it has a thick cable bolted on that goes from the solenoid to the starter body (which matches the pictures I've seen of the standard starter motor) plus the small clip connector.

The question is where do I connect the two hefty electrical wires that currently go to the heavy duty motor on the standard motor?

Not sure which is positive on the standard motor and not sure why the standard motor does not have 2 studs like the heavy duty one does.
Thanks

(must learn how to post photos)

[Darkstar]

hi,

Not got a north Japanese model but i believe they have twin starter batteries, is it possible that one of the heavy duty leads comes from the second battery??

If it is the case i would disconnect the winter battery lead and just use the main battery one.


I may be way off mark here, so hopefully someone will be able to confirm.

[Tony x]

Hello Darkstar
The North Japan models do have 2 batteries but they don't feed separately to the starter motor. My set up is starter battery and leisure battery.
It's the connections to the starter motor that puzzles me - I have 2 copper coloured studs on the heavy duty motor but only one copper coloured stud on the starter I wish to put in.

[Darkstar]

Hi Tony,

Just had a look at the wiring diagrams on this forum, from what i can see you have both leads from the main battery:

One comes straight from the Positive terminal on the main battery, and one come from the main battery with the 30 and 100amp fuse box spurred off from it (i am assuming in the engine bay.)

Both leads on the diagram look like they are connected to the same circuit.

Just a thought, are the two connectors on the heavy duty unit actually connected together inside?, do you have an multimeter to check my theory. maybe a case of just isolating one of the leads,

Sorry can't be more positive, but two heads fumbling about might find the light switch

[Tony x]

Hello,
Cheers for your help Darkstar.
However, the two wires are not connected together inside.
I know this as when I reconnected the heavy duty starter recently, I mistakenly connected these wires the wrong way round. The starter did not work but got very hot very quickly. Hence I'm keen to get the connections correct this time.
Thus, I'm still after information on how to connect up a standard starter after removing a heavy duty one

[Darkstar]

Tony,

Sorry could'nt be of any help,

there must be a way somehow, as i cant see manufactorers having a different wiring loom for viehicles in a differnt area.


I am surprised as to lack of other comments though.

[corrour]

Will have a look at mine today
I suspect the are either :
2 x battery positive
1 x battery pos with a return back to aux fuse box

Do you have a test light or meter?

unless you like sparks don't let either touch the engine if you have batteries to connected.

[rita]

Hi,I cant imagine the two heavy duty cables coming from the battery to the starter (is it an add on ??)You (Normally)only need one heavy duty feed to the starter motor and the ignition trigger (clip 0n )wire for the solenoid.


Good Luck

[Tony x]

Hello and thanks for your help.
The two thick wires appear to be factory fitted - they are both of the same design and look the same age.
I'll get my multimeter out when able - I work 12 hour shifts at the moment, and check to see what each one does.
I suspect one is the usual positive and the other must be an earth. This appears an odd setup since the whole starter motor case is earthed and yet the wire I suspect to be the earth (in fact, both thick wires) connect to the solenoid by terminals that are insulated from the starter casing.
When I finally get a working set up, I'll post the answer assuming I don't fry anything through wrong connections.

The Bongo is a year 2000 with the fly by wire throttle.