Electrical troubleshooting help needed

Hydestone

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I had my deck belt somehow hop off the clutch and got caught above the pulley. It was totally shredded and I had to cut it up to remove it.

I noticed the clutch wire was disconnected, so I plugged it back in.

Now my mower won’t start. I can’t figure out what is happening, here is what I’ve done so far.

Checked the battery - it is just over 12 volts.
Checked ignition switch continuity, it was good.
Checked the solenoid, there was absolutely no spark or engine movement when in bridged the posts.

There was a little bit of clicking that was happening, but now there is absolutely nothing.

I am not sure how to proceed.

Any tips or advice on next steps?

Thanks
 

ILENGINE

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Just because you have 12 volts at the battery doesn't mean the battery is good. Go have the battery tested at an auto parts store. Or you can have somebody hold the leads of a volt meter across the battery post and then just the solenoid and see what the battery voltage drops to.
 

mechanic mark

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please post your model number & then check in line fuse. ILENGINE is correct, remove battery & have any auto parts store load test battery at no cost to you. just make sure if you have to purchase a new battery that cold cranking amps are the same or more than your current battery.
 

Hydestone

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Got the battery tested today...healthy...cold cranking amps were higher than advertised.

Unfortunately, the model number is illegible for the mower. It is a 1998 Craftsman LTX 1000, sort of looks like ????.9174.2?2410. Serial number is 051601B00140

Engine is Kohler CV492S spec no 27506 serial no 3113504713

Also, in the past smoke has come out of my starter, but not recently.
 

bertsmobile1

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If a starter is smoking then either you have been cranking it for way way way too long or there is a build up of debris at the bottom arcing out.
Below is the general troubleshooting guide for a fail to crank situation.

If you would like assistance then do all of the tests and post the results.
It is very difficult to diagnose a problem when all we have to go on is words on a screen.
So much easier if it is there in front of you ready to stubb your toes every day when you walk past.


Before you start, pull the spark plug & try to rotate the engine by hand.
No use checking the electrics if you have a hydraulic lock, seized engine or jambed belt overloading the stater motor.
Assuming the engine turns freely.

I like to start from the starter motor and go backwards .
Do the following 5 tests, regardless of the results from an or all of them as there can be more than one problem and you want to isolate where the problem lies.
Elimination of individual parts is important so you know by the end, the battery, solenoid & heavy power circuits are all in good order.

1) try to jump the starter motor directly from your car or truck.
+ on the starter first then - to a good ground near the starter ( drain plug of lift hook are good )
Starter turns = starter good

2) do the same directly from the mowers battery
Starter turns = mower battery good
No turn = duff battery, recharge it & try again.

3) check for voltage ( + 12V ) at the solenoid trigger wire with the key in start position
3a) same with ground trigger wire ( 4 wire solenoid ) or body of solenoid ( 3 wire solenoid)
( I like to test V from the battery hot terminal to ground terminal rather than ohms as they give funny readings )

4) leave ground jumper in place ( from step 2 ) & try key start.
Starter turns = power connection good but ground connection suspect ( most common )
Confirm it by trying again, extra ground removed

5) Remove the trigger ( thin ) wire / wires from the solenoid.
Ground one on a 4 wire solenoid & bridge from the hot terminal to the other.
Starter cranks = solenoid good.
Solenoid is not polarity sensitive, BUT THE WIRING IS so make sure you remove the thin control wires.
Note a thinner wire on the hot terminal is not a control wire. It is the main power feed to the mower.


From here on things become very mower dependant as starting circuits are getting changed all the time.
Basically the power goes in a loop from the hot side of the solenoid ( saves wire, no other reason ) through the fuse to the B terminal on the key switch then to the PTO switch then to the parking brake switch then to the solenoid trigger switch , easy peasy after you grow the 3rd arm. Use a test lamp and follow the power.
However a lot of mowers with a 4 pole solenoid, run a secondary ground control circuit to the ground solenoid wire through the lap bars.
Then to stop this interfearing with the normal safety function of the ground kill, it goes to a relay with the ground as the switched connection.
These are a PIA as the + control wire to the relay comes from the power loop above and the ground side of the control comes via the normal cut out functions of the lap bars.
Be very careful because if you have a system like this and accidentally send 12V down the ground loop you can fry the magnetos on some circuits..
 

Hydestone

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Ok, I was running short on time and reluctantly going to bring it to the fix it shop. But decided to take one more quick look.

After I tried the first step of rotating the motor...I turned the key and the lawnmower started up. Not sure why, but it’s running!

Now the issue is that the clutch won’t spin and turn the deck belt. It does turn, but it barely moves. When I was trying to get the belt off the clutch, I did manage to nudge something loose in the clutch, possibly a magnet, which I put back into position.

Any thoughts on next moves?
 

Hydestone

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Here is a video I took. It turns when blade engagement knob is pulled out...but only slightly. It also makes a noise, as if something is rattling.

 

bertsmobile1

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Usually that is a sign that the decompressor is not working.
Either because it is busted on the cam or the valve lash is too big & defeating the mechanism.

As for the clutch it needs adjusting.
Usually the air gap is around that of a spark plug .020" to .040" depending upon the clutch.
If the magnets are loose then the magnets can move rather than the clutch.
 
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