Intermittant Solenoid Failure?

[Avenger Bob]

The starter on my 2005 Avenger with a 25hp Kohler will not work some of the time, particularly when it's cold. Sometimes it starts, sometimes it doesn't. I can hear the solenoid working but the starter does not spin. The battery is good and when I jump the battery directly to the starter it starts right up, so I suspected the solenoid. I removed the solenoid and tested it as per the Kohler manual and it works perfectly. It always actuates and I get continuity across the starter terminals every time. The solenoid seems to be sealed and not serviceable.
Has anyone seen a solenoid not work some of the time?

[tattooman]

I had the same problem with my 18hp Briggs. Would start one minute, the next time it would not! Bazoo guy told me to change the starter! I thought the problem was the solenoid! To make a long story short, I changed the starter and my problems went away! Note: this was only a cold weather problem!

[North Country Tough]

Same issue as Avenge Bob with a Frontier,same fix a the tattooman new starter,that said we went with a heavy duty solenoid as used on the old Ford cars for extra measure,and it was only a issue in the cold and intermittent.NCT

[Avenger Bob]

I am reluctant to replace the starter when it does work. If I hook the positive on the battery directly to the starter it runs just fine and the engine starts. The issue seems to be with the solenoid. I notice from some other threads that there have been issues with the ground to the generator.

[ARGOJIM]

Bob, having same issue though will not get to it next week. Did you measure the voltage at solenoid? Next did you measure voltage at output terminal? If your wire or terminal is exposed to starter test voltage there and post if so equiped also.

As an example I've pulled tractor solenoids off, opened them, and found burns and/or corrosion.

Jim


See edit; machine did sink fyi.

[North Country Tough]

Automotive solenoid can be bought super cheap anywhere and simple to wire to know for sure,we tried that on this Frontier and still the same problem but these Briggs are known for starters,my Avenger has never had a issue in a dozen years.

[Avenger Bob]

Good suggestions. I will report back after I have had a chance to look at it again.

[Avenger Bob]

Finally got back to my problem after going South for a few weeks. I noted a similar issue in the thread, "Electrical Help Please" and ran a ground wire directly to one of the mounting bolts on the starter. Problem solved! Now the starter spins up every time. Thanks for your help.