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Long stroke crankshaft for 500/535cc EFI engine including the GT

All English crankshaft for the fuel injected 500/535cc EFi engine including GT

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Starter Solenoid Help

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Starter Solenoid Help
Started at 03:42pm on the 1st January, 2018 by papasmurf
papasmurf Subject: Starter Solenoid Help
Tried to fit our hosts "better" solenoid today to the Electra X (ish) Upon close inspection the old one was fubarred. I am getting into a wucking fuddle fitting the new one, (blown two 30 amp fuses.) Has anyone got a decent wiring diagram? (No problem with the two marge wires the M and B on the new solenoid is a bit of a clue. I suspect just connecting the two thin wires to the existing wiring is the problem. Our hosts state some rewiring is necessary but they don't specify what.
Posted: 03:42pm 1st January, 2018
papasmurf Subject: Starter Solenoid Help
Posted: 04:51pm 1st January, 2018
Adam Subject: Starter Solenoid Help
Hi. I have an Electra X on which the solenoid energizing and earth cables come out of the solenoid body as a pair to a green plug (about 100mm of cable). I would suggest that with your new solenoid on the bench you secure a continuity meter across the terminals M and B and there should be no reading. Then with the meter still connected put battery power (Pos or Neg, doesn’t matter which) to one of the energising coil connectors and flash t’other side of the battery to t’other terminal. You should hear the solenoid engage with a click and continuity meter should give strong reading, disconnect battery and continuity meter. That proves that the solenoid is engaging correctly. I suspect the 30-amp fuse and related ¼” spades are there for stuff fitted to later machines and superfluous to your needs. All you need is the solenoid part so pull out the fuse and put it in the little box on your top shelf marked ‘spare fuses’. From your old solenoid cut the two wires complete with their shared green plug, crimp appropriate female connectors to each wire and fit to your shiny new energising coil connectors. Re-fit solenoid to your machine and wire up just as it was before, ignore the 1/4" spades, should be fine. M and B are self-explanatory. Good luck. Happy Hew Year.
Posted: 06:00pm 1st January, 2018
papasmurf Subject: Starter Solenoid Help
Cheers for that, there is however just one small problem with cutting the wire of off the old solenoid, it is not possible to see which wire is which. I will test the solenoid tomorrow.
Posted: 06:31pm 1st January, 2018
Tim NZ Subject: Starter Solenoid Help
Give some thought to WHY the sol failed?
Typically is is from moisture trapped inside the unit, due mostly to the fact that when any water does get in, it can not drain out.
I mount the replacements sol v/v so that the sealed cover is upmost, terminals facing down so water can not accumulate.

Fun when the solenoid fails with the contacts stuck/welded closed...
Posted: 06:59pm 1st January, 2018
papasmurf Subject: Starter Solenoid Help
Tim NZ, it was very obvious why the original solenoid failed, one of the main terminals was loose in the solenoid. No sign of corrosion just a cheap and nasty solenoid.
Posted: 07:22pm 1st January, 2018
Alan R Subject: Starter Solenoid Help
Hi Guys--------Papasmurf, before you cut anything on the Electra try this}-------1st)... as per that photo, put a piece of tape over the fuse holder and the two spade connectors below it such that you can't see them !!!.....Now what you see left is all that you need to concentrate on...ie the two large nuts and the two spade terminals immediately above them..........2nd)..On the old solenoid, where you have the two thin wires going to that green connector, connect one test meter wire to either of those two wires and the other test meter wire to EARTH ( Ideally the battery NEGATIVE terminal)_........Turn the ignition to ON then turn the key and hold it in the START position.......If the test meter needle deflects to 12v then that is your feed wire from the ign key.........Now go through the same procedure but with the other thin lead....This time you should NOT get a needle deflection because this is the earth wire...

Having said all that it shouldn't matter which way around you connect a solenoid as it's a DC INDUCTIVE device and so is not polarity conscious, but there may be internal wiring that requires it to be connected in one particular way only.....What we need is the wiring diagram for your particular model........
Posted: 08:05pm 1st January, 2018
papasmurf Subject: Starter Solenoid Help
Alan R, it is no problem at all to remove the two spade connectors and the fuse. (They are clipped on as a unit which comes off easily when the two nuts are rewmoved. As for an accurate wiring diagram for my particular model it does not exist it was assembled in a shed in Oxfordshire out of spare parts. I expect after testing the new solenoid I will have to do a rewire of the two thin wire along their entire length. I assume the thin one related to the B terminal can be directly connected to the positive on the battery.
Posted: 08:19pm 1st January, 2018
papasmurf Subject: Starter Solenoid Help
Thanks for all the suggestions. I can't get to touch the bike until next week due to very nasty weather locally over the next two days, after that a trip upcountry in the tin box to a 70th birthday party and onwards see some relatives. (Whether I like it or not.
Posted: 12:51pm 2nd January, 2018
Kentish Man Subject: Starter Solenoid Help
Papasmurf, why not leave the solenoid as is, make up a short cable (approx. 2" long), on one end crimp on a ring terminal, and the other end a female insulated terminal. Fit the ring terminal to the "B" battery terminal, the other end to the right hand 30A terminal. (You will have already connected the solenoid coil connections.) Now you have a fused output that can be used for an accessory, i.e. heated handlebar grips. Just plug into the spare terminal. Note: this will be permanently "live" regardless of ignition key. Hope this helps. Ex Man of Kent now Kentish Man!
Posted: 09:05pm 2nd January, 2018
Kentish Man Subject: Starter Solenoid Help
Papasmurf, why not leave the solenoid as is, make up a short cable (approx. 2" long), on one end crimp on a ring terminal, and the other end a female insulated terminal. Fit the ring terminal to the "B" battery terminal, the other end to the right hand 30A terminal. (You will have already connected the solenoid coil connections.) Now you have a fused output that can be used for an accessory, i.e. heated handlebar grips. Just plug into the spare terminal. Note: this will be permanently "live" regardless of ignition key. Hope this helps. Ex Man of Kent now Kentish Man!
Posted: 09:05pm 2nd January, 2018
Paul G Subject: Starter Solenoid Help
Apologies if I am misunderstanding your post, but only a thick wire goes to the battery positive. The other thick wire goes to the starter motor. The thin wires, one comes from the starter button, the other goes to earth, probably via the clutch switch. I do not have an electra x but that is how these things usually work. If you take the thin wire to the battery the starter will be permanently engaged. You could use the 30 amp fuse (suitably reduced) as the main bike fuse to safe space?
Posted: 11:35am 3rd January, 2018
Paul G Subject: Starter Solenoid Help
Save space! Assumes 30 amp bit and connectors are electrically independent.
Posted: 11:37am 3rd January, 2018
Paulk Subject: Starter Solenoid Help
Concur with Paul G, the spade connections are the "control" (in pairs???) and the large studs are main starter power.
Posted: 09:20am 4th January, 2018
Paulk Subject: Starter Solenoid Help
Adam, If you remove the fuse there will be no current to the energising coils therefore the solenoid will never operate because there is no circuit (according to the notes on the photo). As Paul G explains the 12v "power" comes from the starter button to either of the pair closest to the big studs around the energising coils, through the fuse and out on the other pair of spade connectors and eventually to earth. The act of energising the internal coils make a magnet that throws (pulls???) a large connector between the two large studded contacts allowing full battery power to the starter motor.
Posted: 09:34am 4th January, 2018
Adam Subject: Starter Solenoid Help
Hi Paulk, from what’s been shown and described above and from several years’ personal experience as a field service plant electrician I conclude that, starting from the bottom of Papasmurfs picture, LARGE NUT TO LEFT, marked M, connect to appropriate terminal on starter motor. LARGE NUT TO RIGHT, marked B, Connect to battery positive. This terminal is also connected internally to the 30amp fuse which in turn gives a permanent (ignition not required to be on) feed to the TWO ¼ INCH SPADES for whatever purpose you fancy, maybe a socket for phone charger or torch or whatever. The fuse, fuse holder and large spades are not required for the starter motor to operate. The two SMALLER SPADES are there to energise the coil which in turn passes batt + power to the starter motor via terminal M, one spade terminal would be fed battery positive from the starter button and t’other would be permanently connected to earth, doesn’t matter which. If I knew how to post piccies I would provide a wee schematic for you. Happy New Year, Adam
Posted: 02:38pm 4th January, 2018
Paulk Subject: Starter Solenoid Help
Cool, so the control contacts are the two nearest the studs - now we all know. I must say the photo does not make that clear - well it does if you've seen them before. No pic req'd I now understand. Did seem odd to double up on the spade connectors :-)
Posted: 03:08pm 4th January, 2018
Paulk Subject: Starter Solenoid Help
con't - and the 30 amp fuse seemed big. Thanks for putting me straight and apologies if I've thrown anyone else into confusion.
Posted: 03:13pm 4th January, 2018
Alan R Subject: Starter Solenoid Help
Hi guys-------the answer was already given earlier in a thread headed}---- "Starter Solenoid Testing" with regard to a 12v supply being taken from the solenoid rather than the battery.......but many thanks to Adam for putting it in again..
Posted: 12:03am 5th January, 2018
Alan R Subject: Starter Solenoid Help
Adam, try this}--HOW TO POST PHOTOS}------- https://imgbb.com/ -------
Posted: 12:05am 5th January, 2018

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