Just an overview of how this device works on a Grizzly 660.
Because most GC readers are familiar with the term "solenoid", that's what we'll call it.
Its SOLE PURPOSE
is to "connect" the big red +12v battery lead to the big black starter lead temporarily.
When those 2 leads are connected, the starter motor will crank the grizz. (NOT START THE GRIZZ, JUST CRANK IT)
HERE'S HOW IT WORKS
SEE PIC BELOW:
there are 4 spade terminals built into the top of the solenoid. Lets look at the 2 spade terminals that actually energize the solenoid. See the 2 spade terminals closest to the 2 big screw lugs? That's them. (the 2 blue wires on the plug)
If + (12v) is applied to one of those terminals and - (GROUND) to the other terminal, the solenoid will energize (CLICK) and drop a solid metal bar down inside the solenoid housing connecting the B
attery) to the M
lug (starter M
The - (ground) that is applied to the spade terminal to energize the solenoid comes through the STARTER BUTTON from frame ground...the +(12v) is provided by the CDI after the interlocks are closed (neutral or brake on)
Want to test the starter while its still on the bike because you're not sure whether its good? Here's how to do it.
Get a set of jumper cables..connect one end of each cable to a KNOWN GOOD BATTERY (red to + post, black to -) then clamp the other end of the - cable to the starter CASE and touch the + to the lug on the starter)
Starter cranks the engine? Yes? then the starter is good.
NOTE NOTE NOTE:
The 2 TOP spade terminals and the 2 fuses in the picture HAVE NOTHING TO DO WITH THE OPERATION OF THE SOLENOID.
The Main reason they are put in that location is to simplify the design of the electrical system! (less space, less wire, less weight, less assembly time, less cost)
There are 2-30 amp fuses mounted on the solenoid, HOWEVER the one on the RIGHT side is a SPARE
. Look carefully at the pic, there are no contacts inside that fuse socket)
The power to the LEFTSIDE, active 30 amp fuse comes directly from the red +12v battery post, goes (1) through the +12v solenoid lug (2) through the fuse then (3) exits the solenoid on the upper right terminal (thick red wire in plug).
that thick red wire supplies +12V out to the fuse block (the row of fuses that provide primary power to the bike). The 4th spade terminal, at upper left, is unused.
...if still questions then pm me
PS If this article helped you, please click the "star" button at the bottom of the left hand column under my name...that gives me points for a big drawing for some cool tools