Tough one, need advice from the experts.

1985 RX-7, 126k miles, runs nice once started.

Occasionally makes a horrific noise at starter/flywheel, wait a minute and it starts right up. installed new starter, same.

Occasionally, turn ignition switch and nothing happens. Full power/battery, nothing, no noise at all, no attempt to turn over, wait a bit, and it starts???

Could you guys help me to troubleshoot what the hell is going on.

Thanks,

 

Easy one. I had the exact same issues. Try to start, grind. Try to start, grind. Try to start, rotates like normal. Sometimes it would work on the 1st try, other times it would take several attempts (which could be embarassing if there were people around).

I tried two different used starters, and they all exhibited the same symptoms.

The problem is that Mazda used aluminum battery cables, and they have a tendency to corrode internally. You might be able to get away with simply cleaning up the connections at both ends of both battery cables, but in my case I actually had to replace the cables.

Good luck.



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If the new battery cables don't solve the problem, the ignition switch is the next most likely culprit. Also check the condition of the small black wire the goes to the starter. That one comes from the ignition switch and needs good contact.

 

I've had the exact problem on several different cars, and one of the two above was the case in each situation. Only had one exception, when the starter actually WAS bad, and just my luck i got a used one that ended up bad too.

 

You guy's are awesome, we were minutes away from dropping the tranny and getting after the flywheel. Having custom cables built tomorrow and have our fingers crossed.

THANK YOU

 

Bummer, had 2 new custom battery cables made and no luck. Dropped tranny and got to flywheel and it is a mess. Ring gear teeth badly damaged/worn. Found new ring gear and will sweat it onto flywheel today. Will let you know outcome.

Thanks,

 

The ring gear isn't 'sweated' on. Remove the old one, stick the flywheel in the freezer and the ring gear in the oven, say around 300*. The flywheel won't shrink much but the ring gear will expand enough to so it can be gently tapped onto the flywheel. Some use an acetylene torch to heat the ring gear. If you're careful, that works just as well.

 

New flywheel is in and she is back up and running like a clock.

A lot of work, but hopefully we'll get some more years out of her!

Thanks for all your help.

 

Help...now after weeks of great starts..terrible noise again yesterday. Ignition switch is the last part that I have not changed. HELP!

 

I don't think they did this for all years. I just replaced mine with the new motor and the old guys were copper.

 

Strangely enough I ran into the same thing. I have 2 84's, one 85 and an 83. Both 84's and the 85 were aluminum, but the 83 was copper.