I have been experincing intermittent starting problems with my beloved XJ6 4.2 Sovereign. The starter motor would fail to crank the engine. I found that the starter relay was clicking when the key was turned, and soon found that by disconnecting the red/white lead to the motor and connecting it to the 12 supply, it cranked perfectly. Obviously the fault was in the relay itself.
I opened the relay by easing the crimping of the case and inspected the contacts. These surprisingly were very clean. I applied 12v across the coil and watched the action and saw that a good solid and electrical conection was being made across the contacts. I then noticed that there was a high resistance, (500 ohms) between the upright copper post and the spade connection outside the relay. The rivet that secures the two together had broken down electrically after 28years! All I had to do was drill a 1.5mm hole through the spade terminal and the upright foot beside the rivet and using a small length of 1.5mm copper wire from 1.5 twin & earth cable, solder between the two. I found that by cleaning the sufaces with a small needle file, the solder took instantly. Reassmble the cover by re-instating the case crimping. Re-fit and tested, all is now perfect with the starting.
I hope this may help somebody else in the future.
Regards, Danny.

 

excellent!! I too have found that most of the XJ-6 relays and other electronic parts are repairable with a little patience and observation. usually you end up with a better part than it was originally. (I guess that's called reverse engineering??)

The Wiper and Turn Signal stalk switches are a good example, they can be made better.

 

Good work, Danny.

Cheers
DD

 

Nice work Danny, thanks for sharing
You can guarantee that little gem will help somebody!

You could of course have done a 2 page write up c/w pics and or video though, maybe next time?

 

I've got the same issue on mine, pops up about once a month or so it just refuses to crank. Confused me the first time because it happened shortly after the relay wired into the starter signal from the ignition switch (aftermarket alarm) took a dump leading me to rip all the alarm garbage out. The only difference is I am apparently far lazier than you and, as such, am currently content to jump it off the positive battery post until it starts happening more frequently. When that time comes, I will take the relay apart as you did.

 

I thought i had, but now realiZe i have a Similar issue. wont crank...i wait and it eventually cranks. I cleaned the connections and thought i resolved the issue. Guess i gots to open up the relay.