Originally Posted By: HangFire
Originally Posted By: MalfunctionProne
Appreciating all replies.
Motor develops flat spots?
If it is a brush-type electric motor such as the Bosch Turbine style fuel pump, it can arc under the brushes and develop higher resistance carbonized spots. If it comes to rest under these spots (and it often does due to greater mechanical resistance), the electric motor can be harder to get turning again on the next activation. This is easily avoided by simply waiting a second or two after keying the vehicle "on" before engaging the starter.
The reason is simple physics. Electric motors have a minimum voltage at which they being to spin, and that minimum goes up as the motor ages.
While the starter is engaged, the flooded cell battery is able to deliver huge Amperage to everything that conducts, but the Voltage drops significantly. If any brushed electric motor (wipers, blower, fuel pump) is switched on but not yet turning, the Voltage may be too low to get it turning, but it will appear like a short in the circuit and the battery happily dumps huge current through it. Thus, the arc-welding spots.
I try to turn off wipers, ventilation blowers, and all other motors before starting a vehicle, and I wait a second or two between switching "on" and engaging the starter. As a result I've never had to replace any of my wiper, electric fuel pump, or vent blower motors. Ever. (And I'm not considered to be a person to have great luck with vehicle reliability). I have replaced them for other people, and those other people hop in and hit the starter immediately. I've given the above explanation as to why, but with the exception of a few engineers, no one cares. The vehicle exists for their convenience, and if motors burn out, they reserve the right to complain and not change their behavior.
Great explanation. I knew some but not all of this. But then, I am a Mechanical Engineer!