Service Manual

10.36
ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine.
With the tester on the VDC position, place the
tester's black lead on the battery negative and the
red lead on the battery positive. Reading should
be 12.4 V D. C. or greater.
Remove battery and properly service. Install
fully charged shop battery to continue test.
Disconnect 2-wire connector at the solenoid.
Using a multi-meter, connect the black meter lead
to the Orange/Green harness wire and the red
meter lead to the White/Red harness wire. Apply
the brake and turn ignition switch to the “start”
position. Meter should read battery voltage.
Check for voltage at the chassis 20 Amp fuse
and then check for voltage entering the
ignition switch. Battery voltage should be
present. If battery voltage is present at the
ignition switch, but not the solenoid, replace
the switch. NOTE: The brake MUST be
applied when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
With the solenoid energized, resistance should read about 0.5Ω ± 10%
between the two terminals. If resistance measurement is out of specification,
replace the starter solenoid (see “Starter Solenoid Bench Test”)
Reconnect the solenoid. Connect the tester black lead
to the battery positive and the red lead to the solenoid
end of the battery-to-solenoid wire. Turn the ignition
key to the “start” position. Reading should be less
than .1 V D.C.
Clean the battery-to-solenoid cable ends
or replace the cable.
Connect the black tester lead to solenoid end of
battery-to-solenoid cable. Connect red tester lead
to solenoid end of solenoid-to-starter cable. Turn
the ignition key to the “start” position. Reading
should be less than .1 V D.C.
Replace the starter solenoid.
Connect the black tester lead to the solenoid end of
the solenoid-to-starter cable. Connect the red
tester lead to the starter end of the same cable.
Turn the ignition key to the “start” position. The
reading should be less than .1 V D.C.
Clean the solenoid-to-starter cable ends or
replace the cable.
If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.
Yes
Yes
Yes
Yes
No
No
No
Yes
No
No
Voltage Drop
Testing