FLU419 electrical issues

[terridax]

Hello,
I have a FLU-419 that I bought a few years back. Every once in a while I would encounter an issue where I would go to start it and nothing would happen. Messing with the clutch pedal and continually hitting the start button would eventually get it to fix itself and it would fire right up. I assumed it was something to do with the clutch safety switch, and figured I'd just delete that if it ever got to the point of it no longer working.

Well, now she's stuck and no matter how much I mess with the clutch, I can't get her to even try to turn over. The problem is, I can hear an audible click when depressing the clutch, so I'm fairly sure that's working correctly. I pulled out both the starter button and the keyed switch and tested them both, and they seem to be functioning correctly. I can't find any fuses or relays that seem to be blown/burned out.

While I was messing with things, I realized that sometimes the gauges lose all power, and I can get them all to come back by pushing down on the main power switch. Currently I am working on trying to pull that out so I can test it... I got the cover off that goes over top of it, which exposed two bolts that seem to be holding the switch in. The obvious next step is to remove those bolts, but I am worried that I may not be able to get everything back together if it all drops down. Anyone know how to go about removing the main power switch?

And more importantly, any ideas on things to test to figure out what's causing this?

Thanks in advance,
David

 

[Mogman]

Welcome to the SS forums!

 

[terridax]

I have made progress in testing, but have not been able to find the issue.
I have tested the main power switch that comes right off the battery, the main keyed switch in the dash, the starter button, and the clutch switch... they all needed to be cleaned up a bit, but seem to be functioning and pass resistance tests. What else would be in the way of power getting to the starter? Is there a relay or something that I can check?

Is there any way to bypass the ignition system and jump power directly to the starter to see if the starter itself is the issue?

 

[Pinsandpitons]

have you considered the starter solenoid? Could be a normal starter failure.

 

[Guyfang]

they all needed to be cleaned up a bit, but seem to be functioning and pass resistance tests.

You are assuming. Assuming can and will bite you on the butt. Resistance tests are not reliable. Voltage test is the only real way to test.

Do you have this document?

 

[terridax]

Still struggling to figure out what the issue is. I've read through hundreds of pages on here, gone through all the manuals, stared at the charts for hours... none of it makes any sense to me. Can someone please write out a procedural list of how the starting system is supposed to work? I have no idea if I should even be looking into things like the cold start system, because I cannot figure out if anything in there would actually prevent the start system from working correctly.

The main switch is getting 24v, the clutch switch causes a clicking noise to occur on the passenger side of the motor so I assume it's working correctly, and yet when I hit the start button I get absolutely nothing. Jumping the poles on the starter solenoid gets the starter to spin, but it doesn't engage. Please, someone explain to me how to go about figuring this out as if I'm a complete moron, because I apparently am.

 

[glcaines]

I once had an almost identical problem with my FLU419. Sometimes it would fire right up and other times nothing but a click. I went through the checklist to no avail. I was convinced it was the starter and had it rebuilt, especially after I looked at the starter, which was very rusty and corroded. It was not the starter but the condition of the starter indicated that it needed help anyway and it only cost me $100.00 for the rebuild. It turned out to be one of the five relays under the hood directly in front of the driver. I'm sorry that I don't remember which one was faulty. However, replacing the relay permanently fixed the problem.

 

[Guyfang]

The click you hear is maybe one of these relays. Ad a click is not assurance that it works.
1. KBI Sensor switch.
2. Starter lock out.
3. Starter Repeat Lock out.

 

[terridax]

Welp, went ahead and replaced all 5 of the 5 pin 24 volt relays in hopes that my previous testing of them was insufficient as you all seem to be suggesting, but I'm back at the very same spot, no difference. What next?

 

[glcaines]

I would recommend following the troubleshooting chart in the TM. It is very good and easy to follow.