FLU419 electrical issues

On my FLU419 the relay sockets were not in the same position outlined by the schematic. You can identify which socket is which by looking at the wire numbers. In my case I moved the relay sockets to the correct positions.

glcaines said:

On my FLU419 the relay sockets were not in the same position outlined by the schematic. You can identify which socket is which by looking at the wire numbers. In my case I moved the relay sockets to the correct positions.

Click to expand...

I was wondering if that might have happened on more than one rig. Absolutely agree, there is enough confusion without the components location differing from what the manual calls out. And it is imperative that the identification of the wires are confirmed before moving things around, just in case there were past modifications.

Alright, let's give this one last shot...
After not being able to find any place around me that would rebuild the starter, I opted to just go ahead and buy a new one.


So, I've got everything hooked up how I think it previously was, but now... I've got no power. Anywhere. I've got 24V in the battery series between the poles. I've confirmed that the main power switch (red plastic key) is functioning and am getting 24V on both sides when switch is engaged, testing from the + battery pole to the switch.

Now here's where I'm getting confused...
If I test any sort of constant power source (ie Ignition Switch) while using any of the normal grounding spots (back of fuse panel 1) I get nothing. But if I test a constant power source (Ignition Switch) and put the negative lead of the tester to the + battery terminal, I get 24v. I'm not the smartest when it comes to electricity, so I don't even understand how this is possible... I'm in much need of some hand-holding. What do I do from here?

Sounds like maybe you hooked up the starter wrong. You need to look at EVERY wire you removed and replaced doing the starter replacement. Start at the batteries.

Back for more, aye. Hah! Well, looking back at your photo of the starter, there is a single ring terminal connected to the top large post on the solenoid with two wires coming off of it. One should be wire 11 that supplies power to the ignition switch and the other one should go to the alternator for charging. I'm reckoning that might have got missed or hooked to ground.

Hey guys, my apologies, I should have included a picture and more info yesterday...
Here's what I'm workin' with.


Now, based on the picture I posted previously I know that the bundle of 3 wires goes to the big post, then the other blue wire and one of the white wires goes to the small side post. Since the white wires have two different sized connectors, I'm certain it's the smaller one that goes on the side post with the other blue. That leaves the larger white wire, and a brown wire (w/ black stripe), and another wire that can barely be seen in that pic, but it can only reach the starter mounting stud, so it must go there.

Yesterday, I had the brown wire hooked up to the starter mounting post, assuming it was a ground, and I had the larger white wire hooked up to the large post on the solenoid, with the bundle of 3 wires.

Looking back at the older picture, I'm thinking it might be the brown wire that needs to go to the large solenoid post... can't see anything that looks like the larger white wire, so I'm assuming that needs to go to the ground. So I'm guessing I just need to swap the larger white wire and the brown wire, but I will wait and see what you guys say before I do... really don't wanna fry my brand new starter

Acording to your old picture, the white wire with the large ring went to the bottom large post on the solenoid. I cant see anything of the brown wire so leave that one unhooked for now and hook the rest up. After that, be sure you have voltage at the battery cable on the starter solenoid, if good, retest for power at the ignition.

sethtok said:

Acording to your old picture, the white wire with the large ring went to the bottom large post on the solenoid. I cant see anything of the brown wire so leave that one unhooked for now and hook the rest up. After that, be sure you have voltage at the battery cable on the starter solenoid, if good, retest for power at the ignition.

Click to expand...

IT'S ALIIIIVE!!!
Good call on the other white wire going to the bottom big post... I didn't even see a wire there until you pointed it out, which prompted me to do a CSI investigation of the first photo I posted, and I realized I was actually missing a wire... the battery wire! And I ended up putting that brown wire to the ground point (starter mount bolt), and it seems to be working fine with it there.

I can't believe it... the thing literally fired up on the first crank rotation...

Now to go back through and button up all the stuff I ripped apart, then it's time to put her to some use until the next thing breaks!
Thank you all so much for holding my hand through everything, there's no chance I would have gotten this running on my own. I'll buy you all a steak and some beer anytime you're in CO

Alright, success! Gald you could follow what we were typing on here. Helps to have a extra set of eyes on it too. Have fun.

There are three rules I always follow now, after having this happen to me on lots of equipment, lots of times.

1. If it worked before, and I did anything to the equipment and it doesn't work now, then I did something wrong.
2. If something worked, and someone "Fixed", and it, doesn't work now, someones work needs to be checked and redone.
3. When working with wires, NEVER, EVER, remove wires and mark them with tape, or a felt tip pin. Always use a schematic, (if you have one) and LOOK at the wire numbers, (or colors) and hook it back up by the wire numbers, (or colors). Why? Because someone else could have wired it wrong. When you mark wires with tape of a felt tip pen, you just repeat their mistake.

There is no telling how many hundreds of hours I wasted before I learned these rules.

Glad you got it back into operation!