Pony electric starter problem

[turbofiat124]

Troy Built Pony, model # 13AN77KQ

Problem: I was mowing the other day, shut the engine off to get something to drink, came back and the starter motor would not turn over.

I checked the battery voltage: 12.6 volts

I did some troubleshooting and discovered the 20 amp fuse in the holder adjacent to the soldnoid was blown. Replaced it but still nothing.

After about 30 minutes of troubleshooting I found the only way to get the engine to turn over was to run a jumper wire (using jumper cables) directly from the positive side of the battery to the starter motor. With the ignition switch on.

Went to Lowes and picked up a new starter solenoid and ignition switch for a Troy Built. Replaced the solenoid. Nothing. Replaced the ignition switch. Nothing.

Blew after fuse at some point. But the fuse does not blow all the time for some reason.

Connectors for the safety switche on the seat and the one near the axle were unplugged when I got this mower by the previous owner. I plugged them back up and still nothing. There should be a third safety switch for the blade that maybe he did not unplug that switch has that gone bad? Maybe that is whats preventing the starter motor from turning. Or would that just ground out the ignition and cause the motor not to fire? I have not checked that one.

What else could it be? Could one of the wires going to the ignition switch be chapped somewhere in the wire loom? I'd really had to have to pull the loom out to inspect each and every wire.

What's confusing is there are five or six wires and five pins on the ignition switch. Why so many? Were do all of these wires goto?

Anybody have any idea why this happened all of a sudden?

 

[mechanic mark]

"K&T Parts House Lawn Mower Parts and Chain Saw & Trimmer Parts" download at bottom left of screen, click on pony/bronco manual and go to section 7 electrical section, purchase an inexpensive multi-meter tool and troubleshoot per manual and wiring diagrams at end of manual. I would trace wires from blown fuse and look for bare spots, burn spots, etc. check all wiring and connections ground cables and straps.

 

[turbofiat124]

Thanks for the link. What I really need to know at the moment is if one of the safety switches would prevent the starter from turning or just ground the coil out to where the plug wouldn't fire. I suppose it would have been a good idea to have had the other two connected before this happened to know for sure. I'll print off the diagram. Perhaps all those wires going to the ignition switch goes to those safety switches. Maybe just a matter finding which one.

 

[mechanic mark]

Thanks for the link. What I really need to know at the moment is if one of the safety switches would prevent the starter from turning or just ground the coil out to where the plug wouldn't fire. I suppose it would have been a good idea to have had the other two connected before this happened to know for sure. I'll print off the diagram. Perhaps all those wires going to the ignition switch goes to those safety switches. Maybe just a matter finding which one.

Absolutely yes, that's why I suggested purchasing an inexpensive multi-meter tool so you can locate problem & make repair.

 

[turbofiat124]

I troubleshooted on this mower for three hours the other day and never could figure out the problem!

The wiring diagram says that when the switch is turned to the "start" position, the orange/white wire becomes energized and sends power to the solenoid. At the switch connector the orange/white wire is also connected to a red wire. At the connector 12+ is present (with the key even out of the switch) at these two wires. But at the solenoid there is no power on the orange/white wire. This makes no sense for two reasons.

1) why there is power present at these two wires with the key out of the switch
2) why there is no power at the solenoid at any time.

The solenoid is mounted in the worst possible location for troubleshooting. I even rigged up a bunch of battery jumper cabels and unmounted the solenoid just to be able to check various wires under different conditions.

A guy who I work with who works on lawnmowers says there are like 15 different switches that "fit" these MTD lawnmowers and you have to have the correct one or it won't work. So maybe the one I got at Lowes is the incorrect switch? Maybe the switch went bad to begin with?

I ended up bypassing the ignition switch and wired in a push button starter mounted on the fender. I like to fix stuff right but I needed my mower working.

 

[medic2575]

Im working on a Bronco right now with the same problem. Turn the key switch and nothing. Tested the solenoid and it works fine. Jumped around the solenoid and the tractor would turn over. Multi Metered the key switch and it was so damned confusing that I replaced it with one off of another mower I had around. Still nothing. Safety Switch time I think. You have a blade safety switch that's located near the console on the left side of the mower. Follow the blade engagement arm down till you see it. Getting it out is a royal pain in the ***. My bolts were rusty so I couldn't get a socket to fit down on them. You can get the plug unplugged and test this switch for continuity with a multi meter with some maneuvering. The other Safety switch is for the brake and its tucked between the frame and a panel that houses your steering gear and other attachments. This is the one that is a SOB!!! You cant get to it to unplug the wires and check the switch for continuity without dropping and removing the deck, removing the plate that has all the steering gear attachments and pulleys on it. Then I had to remove the body bolts, shift the body and remove the console just to get to the damned thing. I finally got to it and got it off and continuity tested both switches and the brake switch was good and the blade switch was bad. They are on order and then I have to put the thing back together. All this took me the better part of 5-6 hours of teardown and test but also included testing the solenoid (your right, it is in a terrible place) and practically continuity testing every dang wire on the mower. Im sure my lack of knowledge and experience with checking safety switches lengthened the job substantially but hey, im still learning. Look on You Tube under checking lawnmower safety switches. Theres a dude on there called "Metal in Motion Outdoor Power Equipment Repair". He does a good job explaining how to check Safety Switches.

Good Luck To Ya