I very confused about this starter problem.  I have a 94 sammy.

Here is what I think I know:

Power from the key switch goes to the solenoid directly and pulles a switch to engage the stater directly from the battery.
This switch makes a click noise.  So I don't get if the solenoid is clicking then It has power right.  So at that point the power is not getting to the starter motor from the battery or the solenoid is not working.  I don't understand how bypassing this with the starter fix would help.  Unless the solenoid is not getting enough power but if that is the case I should not be hearing a click noise right???

I feel it must be a battery terminal or solenoid problem.  My battery posts have become too small for the clamps.  Anyone have a fix for that?

My battery posts have become too small for the clamps.  Anyone have a fix for that?

Lead sheet.

You can have a solenoid that will still click, but doesn't have the full battery voltage getting to it (that is what a "clicky starter" is). 
What the clicky starter fix does is take the power from the battery and send it directly to the solenoid (via a relay that is activated by the key switch).  It takes the key switch out of the equation, as far as directly providing power to the solenoid.
Put a clicky starter fix on and see if that fixes the problem.  Even if it doesn't, it is still good to have it on there.

For the battery terminal fix, you can either get the lead caps, or you can use a 3/4" to 1" long piece of 1/2" copper pipe (whatever the height of the battery post is), and cut it down the side and slip it over the battery post.  I've fixed a lot of loose terminal connections using the copper pipe method.

Clever idea on the copper pipe fix! I will have to try that.

Heres a link to the clicky fix I used. It worked great.
http://cgi.ebay.com/ebaymotors/Xtreme-Suzuki-Samurai-Clicky-Fix-ZukiCreations-_W0QQcmdZViewItemQQhashZitem43a8793cfdQQitemZ290589326589QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

Clever idea on the copper pipe fix! I will have to try that.

I used a hose clamp strap.  It was easy to form around the post and is working great for now.

You can have a solenoid that will still click, but doesn't have the full battery voltage getting to it (that is what a "clicky starter" is). 
What the clicky starter fix does is take the power from the battery and send it directly to the solenoid (via a relay that is activated by the key switch).  It takes the key switch out of the equation, as far as directly providing power to the solenoid.
Put a clicky starter fix on and see if that fixes the problem.  Even if it doesn't, it is still good to have it on there.

For the battery terminal fix, you can either get the lead caps, or you can use a 3/4" to 1" long piece of 1/2" copper pipe (whatever the height of the battery post is), and cut it down the side and slip it over the battery post.  I've fixed a lot of loose terminal connections using the copper pipe method.

Well I replaced the starter thinking that was the problem but I was wrong.  It was the key switch not providing enough powerto the solenoid.  I addded a 4 port12 vdc realy and it fires up every time.  My only question is why is the keyswitch not providing enough power.  Just because it';s old.  Do the contacts have more resistance as the wear or what??

The issue with the clicky starter solenoid is due to carbon arc buildup on the contacts which acts as an insulation, the better/larger/more amps the battery has the quicker this will occur.

also if the wire that pushes on to the solenoid has a dirty connection it will cause the terminal to heat up and melt the solder on the back side of the spade connector.  (re-solder the wire to the connector in side the solenoid)

Adding a relay to your key switch will work, but thats not the factory approved method.

May not be the factory approved way, but there are 1000s of samurais out there with that fix and it works fine.
BTW, I have taken starters apart to fix the clicky starter and it has worked on the ones that I have done.

Quote from: Skyhiranger on July 18, 2011, 05:46:26 PM

You can have a solenoid that will still click, but doesn't have the full battery voltage getting to it (that is what a "clicky starter" is). 
What the clicky starter fix does is take the power from the battery and send it directly to the solenoid (via a relay that is activated by the key switch).  It takes the key switch out of the equation, as far as directly providing power to the solenoid.
Put a clicky starter fix on and see if that fixes the problem.  Even if it doesn't, it is still good to have it on there.

For the battery terminal fix, you can either get the lead caps, or you can use a 3/4" to 1" long piece of 1/2" copper pipe (whatever the height of the battery post is), and cut it down the side and slip it over the battery post.  I've fixed a lot of loose terminal connections using the copper pipe method.

Well I replaced the starter thinking that was the problem but I was wrong.  It was the key switch not providing enough powerto the solenoid.  I addded a 4 port12 vdc realy and it fires up every time.  My only question is why is the keyswitch not providing enough power.  Just because it';s old.  Do the contacts have more resistance as the wear or what??

Hmm, you were told of a $10 fix that would likely fix the issue, but you chose to replace that starter instead.  Interesting.  
Most of us don't just pull answers out of our ass.  We either have first hand experience with the issue and fix, or we have read of others issues and fixes, so we can give good answers.
But look on the bright side, you now have a new starter...plus a good spare one.

What Skyhighranger sez!

It may not be factory-approved, but the relay mod is safer - no electrical arcing in old wiring - and cheaper - no need to hunt down a NOS ignition switch with matching key for a gazillion bucks.

...and the amount of BS sometimes is high in some forums - but you can pretty much count on good information in the majpr Suzuki forums - including Zukiworld! 

When in doubt, check the poster's information next to his/her avatar.  Longevity and high post-counts are an indicator of quality information.
 
I'm just sayin'...