Z1OwnersClub GB

Recently I had some trouble with my starter motor solenoid.
When I put a screwdriver across the two protruding terminals, the starter motor turned the engine.
I reasoned it must be a break in the primary coil windings.
I later checked the wiring and found that I had a resistance reading across these smaller wires, across the solenoid coil winding, meaning the wire had continuity.

I decided to dismantle the unit. It looked great externally, even had a nice red /gold circular decal on the unit.
The result was, the slug and its spring were seized up and could not move. The unit was rusted up inside indicated that it had water in it for a period.

This is for info so that you always make sure you hear a loud click as the soft iron core or slug, moves up to make contact with the two main terminals of the unit.
The unit can easily be checked in your hand by connecting 12v across the small earth and black wires.

RegardZ

Hi Garn, how did water get into there so badly in the first place?
Is it not a very dry climate in your part of Australia? Was it through washing the bike?

G'day Jay, As far as I know all of these 40 year solenoids old could have a bit of rust inside, although hopefully not as bad as this one. As stated, it was seized up and the slug just couldn't move to make contact.
These solenoids seldom give trouble, I guess the ingress of water could have just been condensation over a long period. I must admit I was surprised to find it so corroded, particularly as it looked in good condition externally.
RegardZ.
PS. Thanks again for your expertise regarding photo bucket.

Garn 1 wrote:G'day Jay, As far as I know all of these 40 year solenoids old could have a bit of rust inside, although hopefully not as bad as this one. As stated, it was seized up and the slug just couldn't move to make contact.
These solenoids seldom give trouble, I guess the ingress of water could have just been condensation over a long period. I must admit I was surprised to find it so corroded, particularly as it looked in good condition externally.
RegardZ.
PS. Thanks again for your expertise regarding photo bucket.

Well 40 years operation from a solenoid ain't bad going!
That's great info Garn, are they serviceable or do you have to replace
them with new? Never had to open one yet (finger' crossed!)

They seldom play up! You have to unsolder the relay windings from the outside to get them apart, hardly worth the effort, there are usually plenty available ebay etc. They often crack on the black bakelite, through tightening the terminals without hanging onto the 6 mm half nut. This bakelite can be repaired with liquid electrical tape and allowed to cure
RegardZ.