Norton 961 Starter Solenoid Contact Replacement Guide
Download the complete PDF version using the green download button at the top right of this page for an illustrated Norton 961 guide covering starter solenoid contact replacement. This workshop reference explains how to diagnose an intermittent starter caused by worn solenoid contacts and replace the positive starter solenoid contact without replacing the complete starter.
The guide begins with safety precautions, including disconnecting the battery before working on the starter because the starter solenoid cable is live. It then covers disconnecting the speed sensor plug, removing the starter cover, removing the solenoid cap, removing the speed sensor and accessing the solenoid plunger and internal contacts.
Later sections explain how to inspect the plunger contact surface, replace the positive solenoid contact, use the starter contact setting tool, check continuity with an ohms meter and reassemble the solenoid, speed sensor, starter cover, battery cable and fuel tank. The guide also notes that the contact surface should not be cleaned with sandpaper and should only be refinished in a lathe if required.
Contents Include
- Norton 961 starter solenoid contact replacement
- Intermittent starter fault diagnosis
- Battery disconnection safety warning
- Speed sensor plug and sensor removal
- Starter cover and solenoid cap removal
- Solenoid plunger inspection
- Positive solenoid contact replacement
- Starter contact setting tool usage
- Ohms meter continuity check
- Reinstalling the solenoid cap and speed sensor
- Starter cover and battery reconnection
- Fuel tank refitting notes
