Starter motor and burning wires

[jsfnq]

4bd1 Starter not disengaging.

i turned ignition key off. Smoke lots of it from dash.
Removed dash.
Live Brown wires from Engine Connector and starter motor were melted.
I repaired the wires and the engine started but starter motor did not disengage . there was a whirring sound.
I removed and bench tested the starter.
It spins but does not throw out.

Any ideas?  maybe starter clutch ?Repair? replace?

[Carzee]

I'm interested in this problem -I should learn about it in case my truck fails. (touch wood)

I went to Youtube and there are over 100 vids about various starter problems and solenoids. "Starter disengagement problem" came up right away in a search.

I found a neat (short) animated "3D" demo of a starter operating. https://www.youtube.com/watch?v=ogqYG0gjpZU

Also, when wires let out some smoke like yours did it could turn into a disaster. I am wary of 12v hi amp faults ever since I witnessed a Kombi burn to the ground in minutes in a MacDonalds carpark - right beside a Fire Station! Tyres and all. I strongly recommend a battery master switch.

[john.k]

The little high speed geared starters are not economically fixable......simply buy a new starter.,The Taiwanese ones are good,and can be found for around $300.

[yerriyong]

The std hitachi or denso starters are superior quality to any after market replacement, it sounds like your problem is the solenoid, they are simple to dismantle , check the contacts aren't warn and the shuttle moves freely.   

[kman]

Put a multimeter across the output terminals of the solenoid when it is not connected to the battery. If it shows they are closed your solenoid is stuck.