Bad boy magnum 735cc many issues

[800screws]

I’m having a lot of issues with this mower. First I thought it was running out of fuel on straightaways, so I replaced the new fuel filter with another new one and the fuel pump. Ran fine after that.
next time mowing, it randomly dies. Replaced starter solenoid because it has trouble cranking the engine over and would only start wirh a jump pack helping.
So now it died. When trying to restart it would only click.
jumped the new solenoid and it would fire. It ran and then died again.
I can’t get the solenoid to work without jumping across the poles. When it does the engine would turn over and seem to lock up.
I turned the motor over with a ratchet and it sounded like grinding, like the starter was still dragging on the engine. Took the starter off and the shaft has a lot of play. And the motor rotated smoothly.
So I’m thinking that the starter was causing drag on the engine and killing it, but not sure why the engine will not crank. Could a faulty ignition switch prevent it from starting?
Thanks for any help.
I took video of turning it over and it locking up and turning it over by hand but I guess I can’t post videos

 

[Rivets]

I think you are throwing money at it, hoping that you get lucky and replace a bad part. You should be troubleshooting the problem instead. My guess is that you have a bad battery and/or charging system. I would start by having the battery checked and when you have a fully charged battery, have the charging system checked. If this doesn’t solve the problem, report what you did and we’ll give you more advice as to how to proceed. When you come back make sure you post all engine numbers.

 

[800screws]

That’s exactly what I’m doing I’m lost. The battery is at 12.4 and 13.5 when it was running I thought of the charging system a while back when this first started happening but the battery never got below 12 V

 

[Rivets]

You have not told us everything you have done. Maybe you should tell us everything you have done to this point, as we are still in quarantine and can’t stand next to you watching what is happening. Make sure you explain exact parts, ie, fuel solenoid or starter solenoid? From what you’ve posted so far, l’m guessing, JUST GUESSING you have an electrical problem, which complicates things even more if we can’t see the whole picture. First thing I would check now are the battery connections and the ground connection to chassis ground. I also asked for all engine numbers so we know if you have a Briggs, Kaw, Kohler, Ford, Chevy or Evinrude.

 

[800screws]

Ok it’s a Kohler command 735cc. New battery. New starter solenoid and new starter relay. When I turn the key I get just the click. The new solenoid is not closing. When I jump it the solenoid, it has a hard time turning the engine over, like the engine is locking up....which led me to turn it over by hand and find the starter shaft will a lot o play. Do the voltage readings seem correct? I’m not getting voltage on the ignition wire that goes to the starter solenoid when I turn the key. Is there a way to bypass the safety switches till I figure this out?

 

[Rivets]

First, I’ll ask one more time, engine numbers please. They are on a black and silver tag on the side of the shroud. The voltages May be ok, but I don’t know the conditions under which they were taken. Here is a testing procedure to help.




Electrical* problems can be very easy or very difficult, depending on four things.
1. * How well you understand basic electricity.
2. *What tools you have and know how to use.
3. *How well you follow directions.
4. *You don't overlook or assume anything and verify everything.

Remember we cannot see what you are doing. *You are our eyes, ears and fingers in solving this problem. *You must be as accurate as you can when you report back. *The two basic tools we will ask you to use are a test light and a multi-meter. *If you have an assistant when going through these tests it would be very helpful. *These steps work the best when done in order, so please don't jump around. *Now let's solve this problem.

First, check the fuse(s), check battery connections for corrosion (clean if necessary) and *voltage - above 12.5 volts should be good.*

Second, check for power from the battery to one of the large terminals on the solenoid. *One of the wires is connected directly to the battery and has power all the time so one of the large terminals should light a test light or show 12 volts on a meter at all times.*

Third, *check for power at the small terminal of the solenoid while depressing the clutch/brake pedal and holding the key in the start position (you may need an assistant to sit in the seat to override the safety switch). If your solenoid is a four wire solenoid, check both small wire terminals as one is ground and the other is power from the ignition switch. *If your solenoid is a three wire solenoid, make sure the solenoid body is not corroded where it bolts to the chassis of the mower as this is your ground path back to the battery. *If in doubt, remove the solenoid and clean the mounting area down to bare metal. *If there is no power to the small terminal then your problem is most likely a safety switch, ignition switch or in the wiring.*

Fourth, check for power on the other large terminal of the solenoid while holding the key in the start position q(you may need an assistant to sit in the seat to override the safety switch).*

Fifth, check for power at the starter while holding the key in the start position (assistant again).*

Sixth, check your ground circuit back to the battery.

After you have gone through each of the above steps, let us know what happened when you did each step. *At that point we will have great info to tell you how to proceed. *Remember you are our eyes, ears, and fingers, so please be as accurate as possible.

Be as specific as possible with voltage readings as this will help diagnose your problem quicker. *If you do not know how to perform the above checks, just ask and I will try to guide you through it. *Youtube also has some videos and as you know a picture is worth a thousand words.

 

[800screws]

I’m a lineman and have a good understanding of testing. I’m using a fluke meter. I’m not getting power to the small terminal when the key is turned. That’s my first problem! Lol.
min at work. I’ll get the numbera later

 

[Rivets]

Never wanted to insinuate that you don’t know what you’re doing. I’m a retired shop instructor, but I have a very poor understanding of ESP and am not standing next to you. When you can paint me a better picture of what is going on with your unit, I may be able to help you out. Throwing guess at electrical problems will only get you deeper in trouble. As you know when troubleshooting electrical problems you never assume anything and double check everything twice.

 

[800screws]

 

[800screws]

And no no! I appreciate the help. Not sure if a safety switch is preventing the ignition wire to get voltage. Is there a way to bypass the switches for the time being? Do I skin them and twist them together and unplug them?