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DF25A doing nothing with key on/start

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  • DF25A doing nothing with key on/start

    2015 DF25A with 200 hours.

    Was working on a cooling issue (separate thread) and the motor started just fine several times a day for several days. Then, one time, I turned the key to start and it just "clicked". Since then, when I turn on the key, sometimes I get the lights and beep, sometimes not. When I turn the key to start, sometimes I get the starter relay "click", sometimes not. The starter never actually engages. I can pull-start the motor and it runs fine. Battery is fully charged and only 1 year old.

    - Disconnected battery cable from starter relay, connected 12V across the starter relay connector terminals and the relay clicks, so starter relay seems to be OK.
    - On the other side of the relay connector I do not get 12V when I turn the key to start, so I am not getting power to the starter relay.
    - Oddly, if I try to just connect the starter directly to the battery the starter does not respond, so appears something may be problematic with the starter
    - A starter problem does not explain the other behaviors so not blaming this 100% no the starter yet.
    - I can only find one 30A fuse on this motor, and it tested good.

    Based on research here I was suspecting a WW problem, but I have 12.6V at the ignition switch. Any other thoughts on what might be going on or where to look next?



  • #2
    Update: Pulled the side covers and did some more testing with multimeter.

    - neutral safety switch tested good (only have one in the motor, not on the controls)
    - when key is turned on, the fuel pump also turns on EVERY time even when I don't get lights/beep
    - when key is turned to start, the starter relay connector terminals are reading 5.5V
    - found the second 10A fuse, which I read is for the ECU, and it tested good

    So, key-on power is getting to the fuel pump but not the lights/beep. The search continues ... guidance very welcome.

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