Starter Relay (Solenoid) 101 - Yamaha Grizzly ATV Forum
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post #1 of 18 Old 10-01-2012, 10:27 PM Thread Starter
 
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Starter Relay (Solenoid) Part 1 The Basics

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 lug (Battery) to the M lug (starter Motor).

KEY POINT
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)

A CHEAT
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 orange "+REP" button at the bottom of the left hand column under my name...that gives me points for a big drawing for some cool tools ... thanks
waltinbatonrouge
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post #2 of 18 Old 10-01-2012, 11:32 PM
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Somebody sticky this thread ASAP. There is way too much confusion on how this very simple relay works. I hope you keep going in more detail on how to troubleshoot because there are a lot of threads all the time asking the same questions. This stickied will answer a lot before anyone has to post a new thread about the same old thing. Thanks Walt.
 
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post #3 of 18 Old 10-02-2012, 01:03 AM
 
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Go Walt go!

X2 Sticky away mods.

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post #4 of 18 Old 10-02-2012, 09:02 AM
 
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Thread stickied! Good job!
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post #5 of 18 Old 11-27-2012, 12:28 PM
 
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Wonder if y'all could help me.. have700 and the solinoid keeps sticking... when put new one on it works when it fires up starter sticks.. when i shut power off still turns over????? Have top disconnect battery...
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post #6 of 18 Old 10-29-2013, 09:19 PM
 
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I have a 1999 600 Grizzly. I have replaced the relay in the past when it would not start. However this time seems like it's not the problem. I replace the relay years back with the cheaper 20$ has opposed to the $75 dollar at the dealer and it worked fine. Now I just bought a new relay and it still won't start. There is no clicking sound and no lights working at all when the key is on. I crossed the 2 terminals with a screwdriver and it starts fine.
Do anyone have any idea or suggestions as to what may be the problem? I took the push starter switch of and cleaned it , it seems fine, not to sure what else it could be. I did notice when I take out the fuse I get a clicking notice from the other relays next to the rear light.
Any suggestions or anyone know what the problem could be
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post #7 of 18 Old 10-29-2013, 09:22 PM
 
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1999 600 Grizzly starting problem

I have a 1999 600 Grizzly. I have replaced the relay in the past when it would not start. However this time seems like it's not the problem. I replace the relay years back with the cheaper $20 has opposed to the $75 dollar at the dealer and it worked fine. Now I just bought a new relay and it still won't start. There is no clicking sound and no lights working at all when the key is on. I crossed the 2 terminals with a screwdriver and it starts fine.
Do anyone have any idea or suggestions as to what may be the problem? I took the push starter switch of and cleaned it , it seems fine, not to sure what else it could be. I did notice when I take out the fuse I get a clicking notice from the other relays next to the rear light.
Any suggestions or anyone know what the problem could be
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post #8 of 18 Old 12-19-2013, 12:51 AM
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I have a 2007 Grizzly 700, when I bought this bike the starter relay was burned up. well I bought a OEM relay, I didn't realize that they had put a universal starter relay on it and wired it for it too. What I need is to figure out how to fix the wires that connect to the 3 flat posts. would you be able to post a picture of it on a bike for me? Thanks guys!
 
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post #9 of 18 Old 09-03-2014, 01:11 PM
 
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Has anyone ever tried to find and install a higher capacity Starter Relay Assembly for a Grizzley 660...?

Own an 04 660 griz and just realized it's probably 8 years old now. So it's time to do some repairs and probably a few updates. Afterall, who likes to sit at home when one could be cruising around...
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post #10 of 18 Old 10-25-2014, 10:19 AM
 
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Thank you so much. Info is golden.
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post #11 of 18 Old 12-21-2015, 01:41 PM
 
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I will be doing it tomorrow on an 01 Griz 600. I'll let you know how it goes. I am going to use an old Ford solenoid.

Last edited by Blackhawk36; 12-21-2015 at 01:42 PM.
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post #12 of 18 Old 12-21-2015, 01:42 PM
 
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Quote:
Originally Posted by Green660 View Post
Has anyone ever tried to find and install a higher capacity Starter Relay Assembly for a Grizzley 660...?
I will be doing it tomorrow on an 01 Griz 600. I'll let you know how it goes. I am going to use an old Ford solenoid.

I ended up using the one from NAPA auto parts. Works great and has a LIFETIME WARRANTY!

Item: Starter Solenoid
Product Number: BK 7307369
Price: $32.85

Last edited by Blackhawk36; 12-27-2015 at 11:20 AM.
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post #13 of 18 Old 06-08-2016, 02:33 PM
 
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Quote:
Originally Posted by waltinbatonrouge View Post
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 lug (Battery) to the M lug (starter Motor).

KEY POINT
The +12v that is applied to the spade terminal to energize the solenoid comes from the STARTER BUTTON...the ground is generated by the CDI after the interlocks are closed (neutral or brake on)

A CHEAT
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 orange "+REP" button at the bottom of the left hand column under my name...that gives me points for a big drawing for some cool tools ... thanks
waltinbatonrouge
Are you sure the starter button is providing the +12V and not the Ground instead on the other pin ? I am having a problem where the Solenoid is not kicking in, but with a test light I have +12V on 3 pins without touching the starter button !

Last edited by richardv; 06-08-2016 at 02:35 PM. Reason: typo
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post #14 of 18 Old 06-10-2016, 12:47 PM Thread Starter
 
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oops! good catch! just looked again at the schematic..the ground DOES come through the start switch! I fixed the original article so as to not confuse!

thanks much!
waltinbatonrouge
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post #15 of 18 Old 06-11-2016, 12:16 AM
 
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Hello Walt, long time since I've seen you post.
Good to have you back on the board.

Jim,
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COOP45 Primary, 1.5 mm shim, -1.5 mm belt, Purple Secondary Spring, 21 gram weights, weight covers reduced to 29 mm diameter and a 2 mm Cut Cam Plate. 2 heat range hotter plug, Warn Winch, Passenger Foot Rests, Rock Deflectors, Heated Grips and Hand Mitts, Grab Strap, Cooling System Up-Grade and multiple position mirrors.
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