Starter Solenoid: Testing and Inspection

Pull-In Test Of Magnetic Switch:

MAGNETIC SWITCH PULL-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic switch.
2. Connect a 12V battery between S-terminal and M-terminal.
Caution:
This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

3. If pinion moves out, then pull-in coil is good. If it doesn't, replace magnetic switch.

Hold-In Test Of Magnetic Switch:

MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic switch.
2. Connect a 12V battery between S-terminal and body.
Caution:
This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

3. If pinion remains out, everything is in order. If pinion moves in, hold-in circuit is open. Replace magnetic switch.

Free Running Test:

FREE RUNNING TEST
Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows:
a. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter motor terminal.
b. Connect a voltmeter (15-volt scale) across starter motor.
c. Rotate carbon pile to full-resistance position.
d. Connect battery cable from battery negative post to starter motor body.
e. Adjust the rheostat until the battery voltage shown by the voltmeter is 11.5V (for the direct-drive type) or 11V (for the reduction-drive type).
f. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely.
Current:
max. 60 Amps (Direct drive type)
max. 90 Amps (Reduction drive type)

Return Test Of Magnetic Switch:

MAGNETIC SWITCH RETURN TEST
1. Disconnect field coil wire from M-terminal of magnetic switch.
2. Connect a 12V battery between M-terminal and body.
Caution:
This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.

3. Pull pinion out and release. If pinion quickly returns to its original position, everything is in order. If it doesn't, replace magnetic switch.