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When the starter button is pressed, the two fat posts on the starter solenoid should be reading the same voltage (or within a half volt in the real world).
Another way to check this is to touch one probe to the long post, one probe to the short post (at the same time), press start button, it should read less than .5v.
Also, the small stud on the solenoid should also be reading battery voltage when the start button is pressed (within a half volt).
The small post only reading 9v indicates a pretty big voltage drop in the circuit between the post and the battery, this wire goes to the start relay, you could have a poor connection, or a bad relay.
Often the problem with the start relay not putting out sufficient voltage is because the relay is not getting enough voltage, check the wiring between the main breaker and the starter relay.
Last edited by Dan89FLSTC; May 19, 2025 at 07:03 AM.
We are now narrowing the focus and will resolve the issue. I agree with Dan89, the 9 vdc at solenoid is suspicious and probably insufficient to activate the plunger within the solenoid, especially with an alignment issue.
Your new relay may solve this part, but we need to find any voltage drop in the circuit from battery to hot side of relay, to solenoid.
Before you go further try starting it old school, get a big screwdriver and short the long and short posts together on the solenoid , that starter motor should spin. Be careful to touch only the posts with the screwdriver
I'll should be able try jumping the post tonight or tomorrow night. Ordered a relay and typically get stuff within a few days. I'll try a new relay then start checking wires if that doesn't do it. I'll report back soon. Thank you for the direction!
I think the spacer is there (rectangular top just peaking out in photo) If it was not there the mounting tab would be severely distorted trying to torque down the solenoid.
This is not to say the misalignment might be creating an issue.
The spacer for the solenoid is there. My old one was slightly off but I brought up the alignment because of how drastic it is on the new one. I noticed the difference immediately. I'll try bending the bracket.
On the plus side the starter motor did engage when I jumped the solenoid with a screwdriver last night. I'll have the new relay tomorrow and will report back.
New relay same symptom. I'll start checking wiring. Probably won't be until sometime next week. Will follow up with what I find and probably more questions. Thanks guys.
It is NOT the relay, never would be as your solenoid is pulling in. You are seeing a voltage drop across your solenoid primary connections.
Your solenoid mounting is roached. Not sure who made it but it's junk. It's not a missing spacer, it's in there, you can actually see it in the photo's if you zoom in. Get an OEM or and Accel one and you will be good to go.
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