Whilst weather bound in Newlyn there were 2 days with no sun and insufficient wind to operate the wind generator (the harbour is well sheltered from the West) and I had been using power for the heater, cool box etc., so I decided to run the engine for a while. All I got was a click from the starter solenoid, having checked those connections I could and finding nothing the engine finally turned over after several dozen attempts. I stopped and started the engine several times without further problems but at the beginning of a long trip I was not inclined to take the risk of the fault re-occurring.
It was not practical to check every connection and switch but they did not appear to be the problem and the battery voltage was fine so the starter solenoid was the likely culprit. These cost £40 - £50 but there are two types and before I got the motor off I did not know if it was a Bosch or Hitachi. Checking further I found that a new Bosch starter motor and solenoid could be got for £125 (plus vat), as the motor was likely original and 25 years old I went for a complete unit and had it shipped to the harbour masters office at Newlyn.
Getting the old motor off was a challenge, the bolt heads were perfect but with an 8 inch lever on a socket I could not shift either, and I could not get a longer leaver (even if I had one) onto the lower bolt and a longer lever directly onto the top bolt would have risked the lever hitting the aft fuel injector and / or the fuel return union - not to be risked. Also I could not bring a lump hammer down on the leaver to free the bolt.
|The original Hitachi starter motor, the alternator and air filter|
removed, note how clean the retaining bolt is.
|Without the starter motor.|