Join Date: Sep 2006
Thanked 103 Times in 102 Posts
Sled: 2001 600 triple touring 2012 Grand Touri
ATV: 99 big bear, 91 Suzuki Quadrunner
Very easy job to refurbish. Gently spread the 4 metal clips just enough to remove the solenoid from the bracket. Then undo the remaining nuts from the solenoid so the studs can be removed from the bakelite casting. Before you remove the nuts fully from the threaded connectors, wind the nuts to the top to protect the threads and give each a sharp tap to loosen them. Carefully pry out the solenoid and flush the actuator with carb clean that contains a silicone lube. File the four copper contacts to remove any pitting from arcing. Reassemble and test.
This works great for solenoids that stick (starter continues to run with the ignition switch off). If the solenoid does not actuate you may have an open coil, measure the resistance between the two small studs (should be about 5.5 ohms) if it is open and the copper wire wound around the solenoid is not shiny, replace the solenoid as it is likely burnt out.
The ford solenoid would work but it does not have an isolated ground for the coil like the Cat one does. Coil ground it picked up via the frame mount