X2 Starter, click, click

[Johnny340]

Sometimes when I push the start switch, the engine doesn't turn over and all I hear is a click from the solenoid. Sometimes it starts fine. Things I know:
The engine is not locked.
The solenoid works fine.
The start switch works fine.
The battery is 'fine' 11.4v.
When the starter doesn't engage, I can tap it and then it works.
The connections on the outside are all good.
I took the starter apart and found corroded brushes, etc. so I cleaned it all up and reassembled it. The starter worked great on the bench and it worked fine on the engine for a while but now it's intermittent again.

Could the rear of the shaft inside the starter not be grounding well? Is there another place I should check for a bad ground?

 

[Kennay]

FYI, 11.4 volts isn't "Fine"

It's probably a loose/poorly connected ground/power wire or a failing starting solenoid.

 

[Johnny340]

Yea, I know. The battery is on the charger right now. It was stronger and I still had the problem though, thus the single quotes around fine.
I think the solenoid is fine because that is what I hear clicking. When it clicks, there is 11v at the starter.
I'm with you on the grounding idea. I checked the external wires and they are all clean and tight. That's why I was thinking it may be the rear shaft not grounding on the starter body. Does this sound probable?

 

[Kennay]

Well honestly, if you took the starter apart and found corrosion, cleaned it, and then it worked again for a while, I'd suspect it's probably time for a new starter.

when you cleaned the corrosion, did you grease the contacts with dielectric grease or anything like that to keep the corrosion from coming right back?

 

[Freakrider]

try a negative jumper cable from battery to a head bolt w/o paint to ground motor...starter relays need a good motor ground via electrical box which gets grounded via the stator plate ground wire.....

 

[Johnny340]

I will try the jumper ground wire when the battery is finished charging.
I did use dielectric grease and I've only had it out a half a dozen times in fresh water since I had it apart.
I happen to have a good Seadoo starter: PN 278000485
http://216.37.204.206/wps/Seadoo_OEM/Seadoo_PWC.asp?Type=13&A=24&B=2
I recall some 550 guys using some Seadoo starter somehow. Is it possible to make this one work on my X2?

 

[Shonuff]

Well honestly, if you took the starter apart and found corrosion, cleaned it, and then it worked again for a while, I'd suspect it's probably time for a new starter.

when you cleaned the corrosion, did you grease the contacts with dielectric grease or anything like that to keep the corrosion from coming right back?

Agree.

 

[Johnny340]

Starter works perfect on the bench. Brushes are fine and has lots of life left in it.
Charged the battery and it seems better. Maybe time for a new battery.
Thanks