Deep Fried Valeo

[Mr Revhead]

Not tasty at all, I do not recommend!
Pics: https://goo.gl/photos/W73K4kjqnhSdN3k26

My 03 Cali EV has had a starting issue that I thought was Startus Interuptus. KiwiRoy has been helping me a lot via email because I'm also a bit of a wiring muppet  Good bugger that Roy!

Anyway my issue was I would hit the starter button, the solenoid would engage and the starter would give a half hearted rrrr then stop. If you let the button go, and jumped straight back on it, it would go. It's done it ever since I've had it, and according to the previous (first) owner since day one.
So I did the wiring mod (which I cocked up at first) and it didn't improve  much... Then after some more playing around I thought things were working pretty well, so went to go for a ride.
Got nothing more than a single click from the starter every time I hit the button. Starter got HOT! So I pulled it off and this was what was found.

Grease plate detached and worn/fried, magnets dislodged and broken, wear marks on the armature.
Googling the starter part number brings up a LOT of BMW owners having similar failures with their valeos too.
Anyway, thought you lot might like to see some nasty pics so there they go.

[tris]

I think its safe to say "THERE'S YOUR PROBLEM" 

They do go a bit weird. Mine would play silly buggers once a year when I was on the National Road Rally and refuse to play ball despite a good coat of cursing.

A new one fixed it - strange that eh 

[Muzz]

Mine threw that grease plate. Why don't they make it from plastic? Wore the shellac off the ends of the windings but the bare patches were not in contact. Threw the stupid thing away. Still going fine. <shrug>

[twowings]

Yikes! Can't the industrialized world do better than that??

[Muzz]

Yikes! Can't the industrialized world do better than that??

Must admit, my thoughts were, "what the **** were they thinking of". 

I probably I could have put it back in but, why would you?

[Curtis Harper]

http://www.harpermoto.com/main-data-base/electrical/starters-and-charging-systems/valeo-starters-and-parts.html

[Tom]

New one.  IF you had caught it earlier, you probably got away with a new magnet body instead.

[Wayne Orwig]

Clean it up, JB weld the magnets back in or get a new per Curtis. Go ride.