Thanks guys. I'll pull it out, strip it and throw a relay in while I'm at it.

First check your battery is getting full herbs... Before you startn it in the morning, check to see if you have 14V.

I'll check the battery out too then. Its charging at 14.5 but is showing 12.5v when off. I didn't realise it should sit at 13v.

Damo the starter came with the g16A in the green zuk but I'm pretty sure its a 1.3 as I remember seeing it had been ground down when I did the install. I'll check if the commutator needs machining. It's next to the flux capacitor right?

Alright this problem has been getting worse for a month or two. When I try to start my sierra the starter sticks. I can hear the click as it tries to engage but get nothing. After 3 or 4 goes it will eventually turn over and start. Yesterday for the first time I actually had to get out and rock the car while in gear before being able to get it to turn over. I've checked the following.
- cabling to starter
- starter bolts are tight
- ring gear on fly wheel isn't trashed
- the clutch isn't partially engaged

About a week before the problem started I dropped the battery when jumping another zook. I checked it for damage but it seems fine. holds charge, the voltage is fine etc. From my limited battery knowledge if I'd busted one of the cells it wouldn't read over 12 volts, right?

Any one had any experience with this issue?

Clicky Starter Kit
It does more than stop the Clicking Starter that is so embarrassing and very common to the Samurai. It also gives your starter the power it's been starving for by taking the old worn out factory connection out of the loop!
The problem is that the power turning over the starter goes through your key switch. Newer vehicles run a relay putting direct battery to the starter. If you get in and turn the key, and you find your Samurai has the dreaded Click Syndrome. Then this is the fix it needs. Don't delay in getting this high quality ready to go fix. Because waiting can, and will cause damage to your starter.

Enclosed with the kit are detailed, easy to follow instructions, with excellent full color pictures to assist those who might be mechanically or technically challenged. All wire is 14 gauge automotive cross-linked wire ,(OEM is 18ga.) Everything you need to install this is included, except the screwdriver. This kit uses a very High Quality 30amp relay and also includes a water proof heavy duty fuse holder, and 30 amp fuse to protect the battery to starter connection. Every one is run through a series of tests before they get the stamp of approval to be sold, this is so that you can be assured that you are getting the quality part that you expect.


Price: US$25.00

Clicky starter is a well known problem with Sierra's.... So much so that Lowrangeoffroad and others do a plug and play relay kit to fix it.