As far as it is EZ to fix. Even though it may have blown you mind for a while!
Maybe you should be running a ballast resistor (if there is not one there already) What is your "Key On" Voltage to the positive side? Even though I'm not up to snuff on your vehicle, I feel sure it should be between 6-10 Volts while it's running on the positive side. Battery/ alternator voltage will probably work on your coil, points, and maybe condenser. Might keep some spares on hand if you don't have the resistor or a resistor wire to the coil.
Here's the common set-up and voltages out of the solenoid. Pay attention to "I" and how it works during start-up.
Pasting this info in:
"OLD FORD TYPE" SOLENOID SYSTEM, YOUR ACCES, MAY VARY (This was really intended for Jeep CJ People!)
1) POSITIVE CABLE FROM BATTERY
2) OUT TO STARTER MOTOR
3) ON MY JEEP, THIS GOES TO THE ALTERNATOR
4) THIS FEEDS MY FUSEBOX (ALL OF MY ACCESSORIES)
5) "S" WIRE IS FROM KEY, 12V ONLY WHILE YOU ARE "CRANKING"
THIS WIRE ACTIVATES THE SOLINOID'S ELECTROMAGNET, WHICH IN TURN, CONNECTS---A and B INTERNALLY (ONLY THE 2 LARGE GAUGE CABLES CAN HANDLE THE AMPERAGE THE STARTER "PULLS").
WHEN THE SOLENOID IS ACTIVATED, IT THROWS 12V TO STARTER USING THE LARGE GAUGE CABLES (1) POS FROM BATT--THRU SOLINOID INTERNAL CONNECTION--(2) TO THE STARTER, WHILE KEY IS IN "CRANKING" MODE.
THIS IS THE TOTAL REASON FOR A SOLENOID, BECAUSE IT WOULD NOT BE PRACTICAL, TO RUN THE HEAVY CABLES TO AND FROM YOUR KEY SWITCH.
6)"I" WIRE (OPTIONAL), FEEDS COIL "FULL 12V", ONLY WHILE "CRANKING", AFTER YOU RELEASE THE KEY, THE COIL REVERTS BACK TO REDUCED VOLTAGE, SUPPLIED BY YOUR KEY IN THE "RUN" POSITION.
7) "SOLENOID MOUNT" GROUND, UNIT MUST HAVE A GOOD GROUND (BATT. TO ENGINE, ENGINE TO FRAME, FRAME TO BODY [ALL MUST CONNECT, SOMEHOW] )
(3 and 4, ON MY JEEP) ARE FUSABLE LINKS, ALL ARE NOT MARKED, MY #3 IS, #4 IS NOT. ITS SORT OF A "WIRE" FUSE.
IF THEY ARE GOOD, TUGGING ON THEM WILL BE JUST LIKE A WIRE, WHEN THEY ARE "BURNED UP", THEY WILL STRETCH OUT LKE A RUBBER BAND.
If your SOLENOID is good---Just not getting a "Signal" from the Key--We can test that too! (Then you will know which direction to chase this problem)
"S" is the wire that activates the Solenoid----we can sorta cheat it!
Regardless what you do to cheat it, You are suppling 12 VOLTS to the "S"('s) terminal on the solenoid. This is momentary as if you are cranking with the key
STAY CLEAR OF MOVING PARTS!IN PARK--OR EMERGENCY BRAKE ON!
I prefer a "Remote Starter Switch"
A Jumper wire momentarily touched or a Screwdriver touching POS BATTERY or POS BATTERY CABLE to the "S" terminal will by-pass the wire from the key. As long as they are wired side by side, on the solenoid, if you do the screwdriver thing!
This will for sure let you know whether its a Solenoid problem or a Key ( ignition switch not delivering 12 Volts)
This will start your rig if your key is in the "ON" Position
IF YOU HAVE A CJ 5 OR CJ 7---YOUR WIRES SHOULD BE HOOKED UP, EXACTLY AS MINE ARE, IN THE PICS!
JEEP CJ GUYS!--If you changed your coil and did not get the one that says, "FOR USE WITH EXTERNAL RESISTOR ONLY". You NEED TO GET THAT ONE! You have just "DOUBLED" your resistance (w/ one with a internal resistor), and DO NOT HAVE ENOUGH VOLTS TO MAKE IT FIRE! (Your resistor is a "RESISTANCE WIRE" going to the coil already!)
My daughter learned to drive "Willy" at "8", very proficient at "10" when she spent the Summers with me. She insisted on taking her test in him at "16", In this pic she was practicing "hand-cranking" (He does have a starter). Passed the test. No seat-belts (1946, none OEM). When she was told to start up. You KNOW, what she did. Tester said he'd never experienced a test like this one! She's now 23, sorta her "Rental", while she's here. Her birthday is the hood numbers. She was my assistant at "2-3" when we resurrected him from nothing.
On the Willys under hood pic, the white ceramic thingee, on the firewall is my ballast resistor.
Also sending you a CJ wiring diagram, May have to blow it up to see. Look at how the solenoid and the coil "T" together (just above the coil connector, on the positive side)
The wire heading right is the temporary start-up Battery Voltage from "I"----The wire heading left is reduced voltage from either the "Resistance Wire" (as with this CJ diagram)---OR---A ballast resistor, which "Takes Its Place"
When "I" dies at the solenoid when you release the key. My CJ runs off of the Resistance wire (reduced volts) My Willys works the same way, no resistance wire. But has a ballast resistor installed on that same (Plain Jane Wire on Willys). The Ballast resistor provides the necessary reduced voltage. When I built "Willy", I made him a 12 Volt System.
The reason I'm sending you all of this stuff is, I know what can happen to a rig over 40 years old---35 and 65 years for my two! Lot-a-grubby fingers on them, in those amounts of time!
Need More?---I'm here, come back to this post.
Images (Click to enlarge)
Wednesday, May 25th, 2011 AT 5:40 PM