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RCJH77
Samba Member
Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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 Posted: Wed Jan 07, 2026 6:14 pm Post subject: Starter wiring help - 12v solenoid, 6v starter |
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I just wrapped up a 12v conversion on my 1960 Beetle (36hp). Tried to start it for the first time and got nothing. Not a single click. The lights on the dash came on and the headlights, tail lights, and brake lights are all working. Turn signals and wipers are not working.
I know I’m likely dealing with at least a few issues here, but I wanna start with the starter. I know it works, as it was tested successfully out of the car. I also confirmed that the connections are tight. That said, I don’t know for sure that I have it wired correctly for this application. Here’s how I have it wired:
Anything wrong with how it’s wired? I should note that running electrical tests is not my area of expertise, so if there’s a test I should run, please be as specific and detailed as possible. Don’t give me the benefit of the doubt.  |
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OldSchoolVW's 
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Joined: July 03, 2020
Posts: 1635
Location: San Diego
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| Posted: Wed Jan 07, 2026 7:49 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| RCJH77 wrote: |
I just wrapped up a 12v conversion on my 1960 Beetle (36hp). Tried to start it for the first time and got nothing. Not a single click. The lights on the dash came on and the headlights, tail lights, and brake lights are all working. Turn signals and wipers are not working.
I know I’m likely dealing with at least a few issues here, but I wanna start with the starter. I know it works, as it was tested successfully out of the car. I also confirmed that the connections are tight. That said, I don’t know for sure that I have it wired correctly for this application. |
Isn't your starter unsupported? How did you test it out of the car?
Terminal 50 should have the wire from the ignition switch (or from terminal 87 on a hard start relay if you are using one) connected to it. I don't see anything connected to it. I've never seen a fused jumper connected from terminal 30 as you have. Not saying it is wrong to do this, just haven't seen it.
From my '69:
_________________
Tom
"Following distance is proportional to IQ."
"It's okay to think."
"If you don't do it this year, you'll be one year older when you do." Warren Miller
'63 Beetle Sedan
'69 Beetle Sunroof
'70 Beetle Sedan
'73 Type 3 Fastback |
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RCJH77
Samba Member
Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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| Posted: Wed Jan 07, 2026 9:25 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| OldSchoolVW's wrote: |
Isn't your starter unsupported? - Sorry, what do you mean by “unsupported”?
How did you test it out of the car? - I purchased it from a VW shop and the owner hooked it up to power and crossed the terminals with a screwdriver (not sure exactly how he had it connected and which terminals he crossed). It fired up right away.
Terminal 50 should have the wire from the ignition switch (or from terminal 87 on a hard start relay if you are using one) connected to it. I don't see anything connected to it. I've never seen a fused jumper connected from terminal 30 as you have. Not saying it is wrong to do this, just haven't seen it.
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I found this on the internet somewhere, which is why I added the jumper and removed the black/yellow ignition wire: “With the 12v solenoid, the ignition switch contacts can’t reliably handle the higher current draw without burning — so we bypass them completely with the jumper.”
Update: I disconnected the spade side of the jumper and touched it to terminal 50 and it sparked and the starter cranked. I then disconnected the negative side of the battery, connected the jumper to terminal 50 and tried reconnecting the battery. It sparked and the starter cranked. Tried it again, same thing. So it seems the jumper is keeping constant power to the starter when the battery is connected, regardless of the ignition being off, which is highly concerning. How do I correct this? Hard-start relay?
Last edited by RCJH77 on Thu Jan 08, 2026 5:49 am; edited 1 time in total |
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OldSchoolVW's
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Joined: July 03, 2020
Posts: 1635
Location: San Diego
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| Posted: Wed Jan 07, 2026 10:46 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| RCJH77 wrote: |
| OldSchoolVW's wrote: |
Isn't your starter unsupported? - Sorry, what do you mean by “unsupported”?
How did you test it out of the car? - I purchased it from a VW shop and the owner hooked it up to power and crossed the terminals with a screwdriver (not sure exactly how he had it connected and which terminals he crossed). It fired up right away.
Terminal 50 should have the wire from the ignition switch (or from terminal 87 on a hard start relay if you are using one) connected to it. I don't see anything connected to it. I've never seen a fused jumper connected from terminal 30 as you have. Not saying it is wrong to do this, just haven't seen it.
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I found this on the internet somewhere, which is why I added the jumper and removed the black/yellow ignition wire: “With the 12v solenoid, the ignition switch contacts can’t reliably handle the higher current draw without burning — so we bypass them completely with the jumper.”
Update: I disconnected the spade side of the jumper and touched it to terminal 50 and it sparked and the starter cranked. I then disconnected the negative side of the battery, connected the jumper to terminal 50 and tried reconnecting the battery. It sparked and the starter cranked. Tried it again, same thing. So it seems the jumper is keeping constant power to the starter when the battery is connected, regardless of the ignition being off, which is highly concerning. Hope do I correct this? Hard-start relay? |
"Unsupported" refers to the type of starter that has a shaft extending toward the engine when installed. The shaft is supported by a bushing in the bell housing when installed which stabilizes this shaft. When the starter is removed, the shaft is no longer supported. It is my understanding that bench testing this type of starter when the shaft is unsupported by the bushing in the bell housing can internally damage the starter.
Typically a wire coming from the ignition switch with a female quick (spade) connector on it would be attached to terminal 50 on the starter. To extend the life of the contacts in the ignition switch I would use a hard start relay. Perhaps this is what they were referring to as a "jumper" when they mention bypassing the ignition switch?
Glenn has a very clear write up on how to wire up this relay here:
https://www.glenn-ring.com/tech/relay_starter.htm
Note that the wire going to terminal 30 on the relay is fused. I think a vaguely worded description led you to connect the fused jumped as you did in your photo.
Here is how I installed a hard start relay on my '63 (6v):
Yellow - fused wire to relay terminal #30
Red - from ignition switch #50 to relay terminal #85
Green - ground to relay terminal #86
Black - relay #87 to starter terminal #50
_________________
Tom
"Following distance is proportional to IQ."
"It's okay to think."
"If you don't do it this year, you'll be one year older when you do." Warren Miller
'63 Beetle Sedan
'69 Beetle Sunroof
'70 Beetle Sedan
'73 Type 3 Fastback |
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zerotofifty
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Joined: December 27, 2003
Posts: 4368
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| Posted: Thu Jan 08, 2026 3:08 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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Terminal 50 goes to key switch
Not sure what that jumper is doing???
Your axle boots are installed wrong. The seam should not be up do a samba search for instructions on seam placement. But basically seam should be 90 degrees from where it is on yours. This is cause the boot is supposed to flex up and down. Where you got it will over stress the seam
https://www.thesamba.com/vw/archives/info/wiring/bug60.jpg
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Give Peace a Chance.
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RCJH77
Samba Member
Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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| Posted: Thu Jan 08, 2026 3:20 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| zerotofifty wrote: |
Terminal 50 goes to key switch
Not sure what that jumper is doing??? |
In my research on doing a 6v to 12v conversion, I found this, which is why I disconnected the ignition switch wire and added the jumper:
“With the 12v solenoid, the ignition switch contacts can’t reliably handle the higher current draw without burning — so we bypass them completely with the jumper.”
Maybe this isn't necessary, but when I read "ignition switch contacts...burning," I thought that sounded like something I should avoid.
| zerotofifty wrote: |
| Your axle boots are installed wrong. The seam should not be up do a samba search for instructions on seam placement. But basically seam should be 90 degrees from where it is on yours. This is cause the boot is supposed to flex up and down. Where you got it will over stress the seam |
You are the first person to catch that! Thanks for mentioning it. I'll get that corrected. |
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zerotofifty
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Joined: December 27, 2003
Posts: 4368
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| Posted: Thu Jan 08, 2026 4:24 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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I have been running my 1961 ignition switch for over four decades on my 12 volt system
Actually, the 12 volt starter will use about half the current of a 6 volt starter!
V=I x R. Voltage equals the Amperage times the resistance. If you double volts,you halve amps for a given resistance
Your switch is safe!
But you can reduce the current thru the switch by adding a hard start relay near the solenoid
Adding that jumper does nothing to reduce current thru the switch, remove it and instead hook up the key switch to the number 50 terminal on the solenoid, which I assume is the terminal that is unused ( As IF the jumpered small terminal where 50 then your starter will continuously run, it will run till it burns up). That small terminal you jumped is unused in early cars, does not exist on early starter solenoids See the wire diagram I linked in my prior post.
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Sorry About That Chief.
Give Peace a Chance.
Words to live by. |
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RCJH77
Samba Member
Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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| Posted: Thu Jan 08, 2026 4:35 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| zerotofifty wrote: |
I have been running my 1961 ignition switch for over four decades on my 12 volt system
Actually, the 12 volt starter will use about half the current of a 6 volt starter!
V=I x R. Voltage equals the Amperage times the resistance. If you double volts,you halve amps for a given resistance
Your switch is safe!
But you can reduce the current thru the switch by adding a hard start relay near the solenoid
Adding that jumper does nothing to reduce current thru the switch, remove it and instead hook up the key switch to the number 50 terminal on the solenoid, which I assume is the terminal that is unused ( As IF the jumpered small terminal where 50 then your starter will continuously run, it will run till it burns up). That small terminal you jumped is unused in early cars, does not exist on early starter solenoids See the wire diagram I linked in my prior post. |
This makes sense, and puts my mind at ease. I was not feeling good about the constant power situation. Thanks for taking the time to help! |
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RCJH77
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Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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| Posted: Fri Jan 09, 2026 1:53 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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Finished installing the hard start relay this morning and it's now cranking, so...progress!
Fuel is getting to carb, so I must have a spark issue.
Link
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OldSchoolVW's
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Joined: July 03, 2020
Posts: 1635
Location: San Diego
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| Posted: Fri Jan 09, 2026 2:23 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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Check to see if you have 12v at the positive terminal on the coil with the ignition key in the on position. No point in spending time chasing gremlins downstream if the coil isn't getting current.
Did you or a PO happen to put an inline fuse on the coil wire from the fuse panel? If so, it may have blown. Jus' saying ...
_________________
Tom
"Following distance is proportional to IQ."
"It's okay to think."
"If you don't do it this year, you'll be one year older when you do." Warren Miller
'63 Beetle Sedan
'69 Beetle Sunroof
'70 Beetle Sedan
'73 Type 3 Fastback |
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RCJH77
Samba Member
Joined: March 27, 2022
Posts: 274
Location: Johnson County, KS
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| Posted: Fri Jan 09, 2026 4:46 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| OldSchoolVW's wrote: |
| Check to see if you have 12v at the positive terminal on the coil with the ignition key in the on position. No point in spending time chasing gremlins downstream if the coil isn't getting current. |
Just ran this test and it looks like I’m getting 10.6v at the coil.
| OldSchoolVW's wrote: |
| Did you or a PO happen to put an inline fuse on the coil wire from the fuse panel? If so, it may have blown. Jus' saying ... |
No inline fuse. |
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OldSchoolVW's
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Joined: July 03, 2020
Posts: 1635
Location: San Diego
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| Posted: Fri Jan 09, 2026 4:54 pm Post subject: Re: Starter wiring help - 12v solenoid, 6v starter |
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| RCJH77 wrote: |
| OldSchoolVW's wrote: |
| Did you or a PO happen to put an inline fuse on the coil wire from the fuse panel? If so, it may have blown. Jus' saying ... |
No inline fuse. |
You might want to consider adding one on that wire near the fuse panel. If that wire shorts without a fuse to protect it, it and the wires it is bundled with running inside the body will cook ... and that is a headache no one wants to deal with.
_________________
Tom
"Following distance is proportional to IQ."
"It's okay to think."
"If you don't do it this year, you'll be one year older when you do." Warren Miller
'63 Beetle Sedan
'69 Beetle Sunroof
'70 Beetle Sedan
'73 Type 3 Fastback |
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