Hi DJ1. You're thinking of much older starters with "S" and "R" terminals along with the large battery cable terminal. The "S" terminal is for the solenoid and gets 12 volts from the ignition switch or circuit. The "R" terminal, when it was used, is for a relay, meaning a switch that applied full battery voltage to the ignition system during cranking. Going back to breaker points, those systems used a resistor to limit current through the ignition coil to reduce overheating those points. The problem was battery voltage got drawn down during cranking, reducing the spark voltage and making the engine hard to start. Placing full battery voltage, now around 9.6 to 11.0 volts, on the ignition system brought spark voltage back up during cranking. Ford did that with a tap on their starter solenoids on the fender. Chrysler did that with a separate tap on the ignition switch. GM did that with their "R" terminal on the starter solenoid.
That dropping resistor in ignition systems isn't used on newer models, so there is nothing to bypass during cranking. As such, no second small terminal on the starter solenoid is needed. You can find some starters with the "R" terminal when it isn't used or needed as they were holdovers from previous years. GM redesigned their starters and generators for the 1987 model year and really ruined them. Their generators, in particular, went from the world's second-best design, in my opinion, to by far the worst design ever, with little inclination to improve it. The starters went to a permanent magnet, gear-reduction design. They have their own problems, but not nearly as bad as the generators.
When you do have an older starter with the two smaller terminals, it's true they are the same size, and the wires can be accidentally placed on the wrong studs. The starter will not crank that way because you're applying switched 12 volts to a terminal that doesn't go anywhere. 12 volts must be applied to the "S" terminal to activate the electromagnetic coil in the solenoid. That causes a plunger to move and push the starter's drive gear into engagement with the ring gear on the flex plate. Once that occurs, a contact disc makes the high-current electrical contact to send current to the starter motor.
To add a comment about those smaller studs, I ran into some that had a flat spot on one side, with a matching "D"-shaped hole in the terminal. I've heard that was done so the wrong wire couldn't be attached to one of those studs, but I suspect it was more likely done so the terminal wouldn't spin and twist wires as the nut was tightened. I don't remember if both studs had the flat side or if it was just one of them.
Wednesday, March 5th, 2025 AT 4:58 PM