Craftsman T260 Melted Wiring

Just installed the wiring today and all went great. Went to start it, and the relays on the engine wiring and the brand new wiring just click. Nothing at all. I haven't checked any safety switches or anything, but I know for a fact that it's not the solenoid or anything because a new one came installed in the factory replacement harness. This is a MTD replacement, not an off-brand. Battery has been float charging and is at 13.1v.
 
You need to use a voltmeter set on DC volts and check each connection for a voltage drop. A meter Ohm test will not do you any good.

Example: Start at a cable end connection and a battery post. Attach one meter lead to the battery post and the other to the cable end that is connected. Turn the key to the crank position and see if the meter shows a voltage reading. A few millivolts are normal (.001 or .002), but full voltage like 5V is not good.

Next, check the battery cable mount eyelet to the starter solenoid. They are common to develop rust.

Sounds strange but a voltage drop test is the flow of electrons that the meter is reading. This test is simple, but it often confuses people more than it really should.

Check one connection at a time and you will find the problem.

An initial "click" when trying to crank indicates a poor connection.

Every safety switch connection is suspect along with any corroded wire crimp ends.
 
Auto Doc's said:
You need to use a voltmeter set on DC volts and check each connection for a voltage drop. A meter Ohm test will not do you any good.

Example: Start at a cable end connection and a battery post. Attach one meter lead to the battery post and the other to the cable end that is connected. Turn the key to the crank position and see if the meter shows a voltage reading. A few millivolts are normal (.001 or .002), but full voltage like 5V is not good.

Next, check the battery cable mount eyelet to the starter solenoid. They are common to develop rust.

Sounds strange but a voltage drop test is the flow of electrons that the meter is reading. This test is simple, but it often confuses people more than it really should.

Check one connection at a time and you will find the problem.

An initial "click" when trying to crank indicates a poor connection.

Every safety switch connection is suspect along with any corroded wire crimp ends.
Click to expand...
All of the wiring is brand new, so there isn't any rust or corroded wires. I will be working all day tomorrow, but will definitely make time to test some things. Man, nothing is ever '"plug and play" as advertised...😜
 
Finally found the issue, bad keyswitch. The start terminal was melted on the inside, barely noticeable from the outside, covering a few contacts on the inside of the switch, so it didn't contact correctly. Plugged in a known working one and fired right up immediately! Thanks for the help.
 
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