Samurai Clicky Starter Fix (fail, fail, fail, fixed)

Trying to fix the clicky starter ignition switch on my Suzuki Samurai. Experimenting with different ways to try to get the switch working better.
What eventually worked: Contact surfaces clean, level, and modified a bit. I also replaced the three springs with a silicone "spring". I put more effort into it than it is worth, but it seems to work!
For the Hwy83 SUZUKI video check here:
• Clicky Starter FIX! Re...
For my other samurai build videos check here:
Spray on Raptor liner:
• Samurai - Raptor Liner...
Rocksliders and rust removal:
• Samurai Rock Sliders &...
Warn M8000 Winch
• Samurai Warn M8000 Winch
Shrockworks front bumper
• Samurai Shrockworks Fr...
Rally Tops 1 Piece Removable Hard Top
• Samurai Rally Tops Rem...
Old Man Emu lift kit:
• Samurai Old Man Emu Li...
Corbeau rear seat upgrade:
• Samurai rear seat - Co...
Project intro:
• Samurai Project Intro

[@jmac203]

Your patience is admirable! I’d of thrown that thing across the garage on the second attempt.

[@lapincretin2616]

Quelle aventure. Merci, j'ai le même problème ! What an adventure ! Thinks, i have the same problem !

[@earundel1327]

do you happen to have the part number for the starter ignition switch? Thanks.

[@jacklandismcgowan1413]

Excellent video . How has the repair been working?

[@dr.dansgarage]

Thanks. So far it’s still working well!

[@jacklandismcgowan1413]

@@dr.dansgarage I’m going to start this project tomorrow . I’ve owned my 87 Sami going on 21 years. Thanks for the response 😎👍

[@lapincretin2616]

Then, the problem is that springs are not enough hard ? And why the contact is not large enough ? The contact is too worn out or too erded ?

[@BryanRock505]

thats a beauty rig. are you thinking on new paint?

[@dr.dansgarage]

Thanks! Yeah, will spray some fresh red at some point

[@cozysajan4813]

where do u find parts for samurai in canada?

[@dr.dansgarage]

I pretty much always order from the states. Rockauto, lowrangeoffroad, amazon, etc. Most places have reasonable shipping costs to Canada; otherwise I go elsewhere.

[@cozysajan4813]

@@dr.dansgarage Thanks a lot for reply,I recently bought 1.3 1988

[@4LO_Jeep_Bro]

Dr. Dan. Have you considered the "clicky starter" fix? It's a pretty common problem with Samurai. It bypasses the switch and sends power straight from the battery to the starter. It's about $35 and takes about an hour to fix. www.lowrangeoffroad.com/suzuki-samurai-clicky-starter-upgrade-kit.html

[@dr.dansgarage]

Yeah I have seen that. When I started working on the switch I was hopeful it wasn’t necessary. Now I see why it’s a common mod. So far my repaired switch is good, but I could see adding the relay at some point.

[@speedfreak8200]

A $5.00 relay, couple ft. Of wire, butt connectors, build your own.... I've never had much luck only cleaning the ign. Contacts

[@adamsupan]

I had a similar problem with mine. The small contact and the one next to it where the arcing takes place were shorted together inside the black plastic. It would sometimes arc and melt the solder on the switch. Just replace that switch. They're cheap.

[@MuniNadan-rk4jd]

That thing got so thin you keep sanding it. Get a new ignition barrel a universal one will also work cost around $35aud. Maybe your starter solenoid is bad but you think it's the switch. Turn on ignition and go touch a screw driver across starter's positive and negative solenoid terminals to see if it starts directly that way.

[@dr.dansgarage]

When I did this, a replacement ignition was out of stock everywhere. I've since purchased and received a new one but I haven't had to replace it yet because the repaired one is still working fine.

[@adamsupan]

That clicking is your starter solenoid, not the switch.

[@dr.dansgarage]

Yes absolutely. The root problem was poor contact at the switch; but the actual clicking is coming from starter solenoid.