Solenoid/starter replacement

[EternalArianne]

Here is the serial number: 362116

Also, as a test, I tried jumping the red wire post on the solenoid (hot from battery) to the small blue wire (from ignition switch), and it fired right up immediately. I had the key in the run position, not start.

So to summarize the issue so you don't hafta re-read all the posts, sometimes when I turn the key I get nothing (no dash lights). Sometimes when I turn the key I hear a thunk (which I assume is the Bendix kicking in) but no starter spin. Jumping the two large posts on the solenoid makes it spin but it won't start unless the key is in "start". Jumping the hot post to the blue start wire makes it start if it just have the key on "run". Does that help narrow it down?

[R Bedell]

Wiring diagram sent. Check your email.

[EternalArianne]

Thanks Roland, I'll look it over. Hopefully I can figure it out.

[EternalArianne]

Well the ignition switch definitely bad burned contacts I'm surprised it worked at all. Replaced it but still having same issue. I'll keep looking...

[EternalArianne]

Ok I've narrowed it down to an issue with the blue ignition wire to the solenoid. If I unplug it and turn the key, it reads 12v. But while plugged in I'm only getting 7v on the terminal. If I jumper 12v from the battery cable to that connector it fires up. I'm going to try replacing the spade connector on the blue wire and see if that fixes the issue. It just very well be loose or rusty or both.

[R Bedell]

But while plugged in I'm only getting 7v on the terminal.

There is your problem. With a DVM, trace back to where you have a constant 12V on that circuit. Once you find where it drops to 7V, fix that issue.

[RLause]

Basic Troubleshooting 101

[EternalArianne]

Does anyone know if the starter from a newer Kohler engine would work? I like the idea of having the solenoid and starter being separated instead of bolted together.

I would think that if the bolt pattern matches up to the engine and the Bendix has the correct teeth count, it should work? Then I can just wire up the solenoid and bolt it to the frame elsewhere.

[Billy-O]

Originally Posted by EternalArianne

Does anyone know if the starter from a newer Kohler engine would work? I like the idea of having the solenoid and starter being separated instead of bolted together.

I would think that if the bolt pattern matches up to the engine and the Bendix has the correct teeth count, it should work? Then I can just wire up the solenoid and bolt it to the frame elsewhere.

Honestly, I think you should either try to properly repair your existing starter/solenoid unit or replace the entire unit. If this were mine, I'd try repairing but if I find this too challenging, I'd simply replace it given that a new starter/solenoid can be had for less than $100 if I'm correct.

To jerry-rig a starter with a separate solenoid would likely be more trouble than it is worth. After all, to reuse the solenoid that you already have separated from starter would be mute.....this solenoid that you have looks to be a plunger type and needs to be mated with the starter in order to work properly.

[EternalArianne]

Yes I think I will replace the entire thing. Doesn't look like it's made OEM anymore so aftermarket will be the way to go. Found one for $70 I'll take a chance on it.