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Originally posted by Not a Number One of my part time jobs in college was fixing pinball machines. These are basically dozens of solenoids and relays. If a solenoid is binding it is usually because of misalignment due to improper installation or wear of the mechanical linkages causing misalignment or swelling of the sleeve around the plunger. Swelling is mostly due to overheating of the coil but could be caused by defects in the materials or lubrication by substances incompatible with the material of the sleeve.
Sanding or polishing the plunger is only a temporary solution at best as there is also wear to the sleeve. This wear is more often than not uneven. Without addressing the misalignment issues you'll get further increased wear and malfunction. Without addressing the wear issues in the sleeve and change the tolerances by sanding/polishing the plunger and/or sleeve you'll get further increased wear and binding.
Sure, we would sand and lubricate these parts but only as a temporary stop gap solution to get the machine up and running (and making money) long enough for us to get the parts and replace them.
As I understand it, the problem is not side clearance of the plunger, but the length of the arms and clearance with the magnet. Shortening the arms ever so slightly seems to prevent the plunger from sticking to the magnet.