Subsection XX (STARTING SYSTEM)

STARTING SYSTEM
SERVICE TOOLS
Description Part Number Page
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 3, 5
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 3–5

SERVICE PRODUCTS
Description Part Number Page
DIELECTRIC GREASE ................................................................... 293 550 004 ............................................. 7

SSS DS
START/STOP SW
(Normally open)

RD/WH 2 1 1 2

RD/WH
YE/RD

BK/YE
BK
1 4 6 9
JT RD/BU STEERING

JT VT
YE/RD

BK/YE
BK
RD/WH
RD/BU

RD/BU

RD/BU
RD/BU

BK/VT

VT
VT

B-D1

B-E4
B-F2

BK/VT B-H2
C6
A6

A4
C5

B2
C4

B6

B4
(F2)
FUSE BOX (FB1)

5 AMP

ECM
15 AMP

(F1) 10 AMP

RELAY
B-M4

B-L4
(F3)
C3

B1

VT/GY

BN/YE
VT/GY
RD

JT-1 VT/GY
VT/GY
VT/GY
RD VT/GY
A

BN/YE
B

BK RD

RD
BATTERY STARTER
MOTOR
STS
BK
STARTER SOLENOID

smr2014-034-100

smr2012-031 1
Subsection XX (STARTING SYSTEM)

GENERAL NOTE: This subsection assumes the problem is

related to an electrical component of the starting
BASIC STARTING SYSTEM system. If the starting system tests good, ensure
engine and jet pump integrity. Refer to applicable
OPERATION subsection.
Engine Cranking Conditions
The following conditions must be met to allow en- DIAGNOSTIC GUIDELINES
gine cranking: NOTHING HAPPENS WHEN START/STOP
1. The tether cord securely installed on the en- BUTTON PRESSED
gine cut-off switch and it's recognized by the
1. Battery not connected
ECM as valid (2 short beeps)
- Connect battery.
2. START/STOP button pressed and held.
2. Burnt fuse
Starting System Logic - F2 fuse: (START/STOP switch circuit).
When the ECM detects a tether cord, it allows - F3 fuse: (main DC power fuses).
engine cranking by providing the ground to the
starter solenoid when the START/STOP button is 3. Defective relay or related circuits
pressed and held. - Test relay and circuits.
If the START/STOP button is activated while the 4. Defective START/STOP switch
throttle lever is depressed more than 60%, the en- - Test START/STOP switch, wiring and connec-
gine will crank but will not start (engine drowned tions.
mode).
ENGINE DOES NOT CRANK
If the START/STOP button is held after engine has
started, the ECM automatically stops the starter if 1. Burnt fuse
engine speed reaches at least 1400 RPM. - F1 fuse: (starter solenoid power) Carry out a SO-
If the START/STOP button is pressed when the LENOID INPUT VOLTAGE TEST (Solenoid Coil).
engine is running, the engine will shut down. 2. Discharged battery
- Recharge and test. Refer to CHARGING SYSTEM
TROUBLESHOOTING subsection.
3. Battery connections
DIAGNOSTIC TIPS - Check/clean/tighten.
NOTE: It is a good practice to check for fault 4. Poor/bad or corroded ground contacts (engine,
codes using B.U.D.S. as a first troubleshoot- battery ground cable, starter etc.)
ing step. Refer to DIAGNOSTIC SYSTEM AND - Check/clean/repair, refer to POWER DISTRIBU-
FAULT CODES subsection. TION AND GROUNDS subsection.
Starting system failures are not necessarily re- 5. Starter solenoid
lated to the starter but may be due to one the
- Test solenoid, wiring and connections.
following:
– Starter solenoid fuse F1 6. Damaged starter or ground cables
– Battery, refer to CHARGING SYSTEM - Carry out SOLENOID DYNAMIC TEST.
– START/STOP button 7. Obstructed starter drive gear assembly
– Starter solenoid - Check/repair, refer to PTO HOUSING AND MAG-
– Engine cut-off switch NETO.
– ECM 8. No ground provided by ECM to starter solenoid
– Wiring/connections. - Refer to CONTINUITY TEST OF START/STOP
Check these components before removing the SWITCH CONTROL CIRCUIT in this subsection.
starter. 9. Engine cannot be rotated (possibly seized or jet
pump blocked)
- Refer to ENGINE subsection.

2 smr2012-031
 Subsection XX (STARTING SYSTEM)

ENGINE CRANKS SLOWLY START/STOP SWITCH

1. Loose, corroded or dirty battery cable connec- START/STOP Switch Circuit Continuity
tions Test
- Check/clean/tighten.
REQUIRED TOOLS
2. Discharged/weak battery
- Recharge and test. Refer to CHARGING SYSTEM ECM ADAPTER TOOL (P/N 529
subsection. 036 166)
3. Low voltage from starter solenoid
- Carry out a SOLENOID DYNAMIC TEST. FLUKE 115 MULTIMETER
(P/N 529 035 868)
4. Damaged starter or ground cables
- Carry out SOLENOID DYNAMIC TEST.
1. Remove START/STOP switch fuse (F2).
5. Worn starter Disconnect connector "B" from the ECM, refer to
- Check. WIRING HARNESS AND CONNECTOR subsec-
tion.
STARTER TURNS, BUT STARTER DRIVE
DOES NOT MESH WITH RING GEAR Install ECM ADAPTER TOOL (P/N 529 036 166) on
ECM harness connector "B".
1. Worn starter drive gear/starter gear/ring gear
Set the FLUKE 115 MULTIMETER (P/N 529 035 868)
- Replace worn parts. Refer to STARTER GEAR in to .
this subsection and PTO HOUSING AND MAG-
NETO subsection. Press and hold the START/STOP switch and test
for continuity of the switch circuit as per following
2. Defective drive
table.
- Replace starter drive. Refer to MAGNETO AND
STARTER subsection. CONTINUITY TEST OF START/STOP SWITCH
CIRCUIT (BUTTON PRESSED AND HELD)
STARTER KEEPS RUNNING
ECM
FUSE BOX RESISTANCE
1. Shorted solenoid winding CONNECTOR B
- Replace solenoid. Close to 0
Pin C5 B-D1
2. Melted solenoid contacts (continuity)
- Replace solenoid.
2. If the reading is as specified, the START/STOP
3. Sticking or defective starter drive switch and its wiring are good.
- Lubricate or replace. Refer to MAGNETO AND 3. If a high resistance or an open circuit is mea-
STARTER. sured, carry out START/STOP SWITCH CONTI-
NUITY TEST.
PROCEDURES
START/STOP Switch Continuity Test
WARNING
REQUIRED TOOLS
When carrying out any kind of maintenance
on the starting system, always disconnect the Diagnostic harness (P/N 529 036 276)
battery ground cable. This will eliminate the
possibility of shorting out a power cable, and FLUKE 115 MULTIMETER
generating a spark which could result in a fire (P/N 529 035 868)
or and explosion. Do not place any tool on
the battery. 1. Remove START/STOP switch fuse (F2).
2. Disconnect the steering connector.

smr2012-031 3
Subsection XX (STARTING SYSTEM)

smr2014-034-009_a smr2014-034-010_a

1. Steering connector 1. Steering connector

2. Starter solenoid
3. Connect the diagnostic harness (P/N 529 036
276) to make an in-line connection between the Solenoid Input Voltage Test
disconnected connector. (Solenoid Coil)
4. Use the FLUKE 115 MULTIMETER (P/N 529 035 REQUIRED TOOLS
868) and select .
5. Measure resistance through switch as per fol- FLUKE 115 MULTIMETER
lowing table. (P/N 529 035 868)

CONTINUITY TEST OF START/STOP

SWITCH CIRCUIT 1. Make sure F1 fuse is powered and in good con-
dition before testing.
DIAGNOSTIC
SWITCH 2. Disconnect solenoid connector.
HARNESS RESISTANCE
POSITION
CONNECTOR
Released Infinite (OL)
Pressed and Pins 1 and 4
Close to 0
held

If the switch does not test as specified, replace

the START/STOP switch.
If the switch tests as specified, check for an open
circuit between connections as per table:
OPEN CIRCUIT TEST
CIRCUIT CONNECTIONS RESISTANCE
smr2014-034-001_a
Steering
Fuse box pin C5 1. Solenoid connector
connector pin 1 Must be close
Steering ECM connector to 0 3. Set the multimeter to Vdc.
connector pin 4 B, pin D1 4. Install tether cord on the engine cut-off switch.
5. Press the START/STOP button to activate ECM.
STARTER SOLENOID 6. Measure voltage within 3 minutes after
Starter Solenoid Access START/STOP switch has been depressed.
The starter solenoid is located beside the fuse box
and it is accessible through the LH access open-
ing.

4 smr2012-031
 Subsection XX (STARTING SYSTEM)

SOLENOID INPUT VOLTAGE TEST

(SOLENOID COIL)
VOLTAGE
TEST PROBES
READING
Pin A (VT/GY) Battery ground Battery voltage

smr2014-034-002_b

If test failed, repair or replace wiring/connectors.

If test succeeded, carry out a SOLENOID COIL
RESISTANCE TEST.
Solenoid Coil Resistance Test
smr2014-034-002_a REQUIRED TOOLS

If test succeeded, carry out a SOLENOID CON- FLUKE 115 MULTIMETER

TROL CIRCUIT TEST. (P/N 529 035 868)
If test failed, carry out a START/STOP SWITCH
CIRCUIT CONTINUITY TEST. 1. Set multimeter to .
Solenoid Control Circuit Continuity 2. Disconnect solenoid connector.
Test 3. Measure solenoid coil resistance as per follow-
ing table.
REQUIRED TOOLS
SOLENOID COIL RESISTANCE TEST
ECM ADAPTER TOOL (P/N 529 SOLENOID CONNECTOR RESISTANCE
036 166)
Pin A Pin B 4.5 to 5.5
FLUKE 115 MULTIMETER If test fails, replace solenoid.
(P/N 529 035 868)
Solenoid Dynamic Test
1. Set the multimeter to .
REQUIRED TOOLS
2. Disconnect connector "B" from ECM, refer to
WIRING HARNESS AND CONNECTOR subsec- FLUKE 115 MULTIMETER
tion. (P/N 529 035 868)
3. Install the ECM adaptor tool on ECM harness
connector. 1. Ensure fuse F1, battery, and starter solenoid
4. Test continuity of wiring from solenoid to ECM are properly connected.
as per following table. 2. Make sure the battery ground cable is securely
SOLENOID CONTROL CIRCUIT TEST
connected to the engine. Refer to POWER DIS-
TRIBUTION AND GROUNDS.
SOLENOID ECM
CONNECTOR CONNECTOR B
RESISTANCE 3. Depress the throttle lever to place the ECM in
engine drowned mode. Hold throttle lever in
Close to 0 place using a rubber band
Pin B (BN/YE) B-L4
(continuity)
4. Set multimeter to Vdc.
5. Crank engine.

smr2012-031 5
Subsection XX (STARTING SYSTEM)

6. As engine is cranking, measure the voltage as

2 1
per following tables.

M
SOLENOID DYNAMIC TEST (ENGINE CRANKING)
TEST PROBES VOLTAGE (DC)
Solenoid
Battery ground Battery voltage
battery post

2 1 smr2009-034-010_c

1. Starter motor
2. Starter solenoid

M If test failed, replace solenoid.

If all solenoid dynamic tests are as specified, re-
place starter.
11. Remove rubber band from throttle lever.
12. Reinstall removed parts.
smr2009-034-010_a

1. Starter motor
2. Starter solenoid Solenoid Removal
1. Disconnect battery. Refer to CHARGING SYS-
7. If test failed, check battery positive cable (from TEM subsection.
battery to solenoid).
8. If test succeeded, continue with next step. WARNING
SOLENOID DYNAMIC TEST (ENGINE CRANKING) Always disconnect the BLACK (-) battery ca-
ble first and reconnect last.
TEST PROBES VOLTAGE (DC)
Solenoid 2. Disconnect solenoid cables.
Battery ground Battery voltage
starter post

2 1

smr2009-034-010_b
smr2014-034-003_a
1. Starter motor
2. Starter solenoid 1. Solenoid cable nuts

9. If test failed, carry out a SOLENOID INPUT 3. Disconnect starter solenoid connector.
VOLTAGE TEST (SOLENOID COIL).
10. If test succeeded, continue with next step.
SOLENOID DYNAMIC TEST (ENGINE CRANKING)
TEST PROBES VOLTAGE (DC)
Solenoid Solenoid
0.2 Vdc max.
battery post starter post

6 smr2012-031
 Subsection XX (STARTING SYSTEM)

smr2014-034-006_a
smr2014-034-004_a
1. Cable from battery
1. Starter solenoid connector 2. Cable to starter motor

4. Remove both screws retaining the solenoid. NOTE: Apply DIELECTRIC GREASE (P/N 293 550
004) under and over each connections and make
sure each nut are well covered.
TIGHTENING TORQUE
Solenoid cable retaining 4 N•m ± 0.5 N•m
nuts (35 lbf•in ± 4 lbf•in)

4. Close or slide protective caps.

5. Reconnect battery and test starter solenoid op-
eration.

STARTER
smr2014-034-005_a
For starter information refer to MAGNETO AND
1. Solenoid retaining screws
STARTER subsection.
Solenoid Installation
Reverse the removal procedure and pay attention
to the following.
1. Secure solenoid on its supports using previ-
ously removed screws.
TIGHTENING TORQUE
Solenoid retaining 2 N•m ± 0.5 N•m
screws (18 lbf•in ± 4 lbf•in)

2. Connect solenoid connector.

3. Reinstall cables to solenoid as shown.

smr2012-031 7