Cushman Turf Truckster Starter

namyot11

I recently picked up a 1990 Cushman Turf Truckster model # 898530 with the 22hp OMC engine. Ran well the first few days, then the starter was hit and miss, now the starter doesn't engage. I hear one click from under the dash when I turn the key, but get nothing when the key goes into the start position. The battery is fully charged so I'm thinking it's a bad starter motor. I don't exactly know where the solenoid is to check it out either. It's probably been 30 years since I've diagnosed any starter issues, so any help would be appreciated.

BGW

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CharleyL

Follow the heavy positive lead from the battery. It will lead you to the starter solenoid.
With a heavy piece of wire, touch jumper from the battery positive lead terminal on the solenoid to the other heavy wire terminal usually on the opposite side of the solenoid. If the starter tries to start the motor you most likely have a defective starter solenoid. When you turn the key to start, the starter solenoid should also be where the clicking noise is coming from. Before you buy another starter solenoid make certain that the battery connections, the heavy wire connections on the starter solenoid and the heavy wire connection on the starter are all clean and making good connection. Take them apart and clean the connections with a wire brush, but remove the battery ground connection before doing this to avoid sparks and possible fire. When everything is back together and tight, including the ground connection to the battery, try starting the motor again. If the starter fails, the starter solenoid is the likely suspect. An auto parts dealer can likely provide a close match if you take the old one to the store.

Charley

namyot11

Thanks for walking me through the procedure. I will try it next chance I get, hopefully tomorrow. I'll post the results.

Yamaha_G1

I agree with CharleyL but one other thing I would check is the battery under load. Have you tried to jumpstart it?

It may show charged and even 12 volts without load but if you check it with a meter while you try to start the Cushman if the voltage drops significantly then you have a dead battery.

namyot11

Well, after a few days bout with the flu, I got back out there to try starting the Cushman again. Turning the key t start does nothing. I jumped the large leads on the solenoid and it does turn over. I also disconnected all the wires to check connections. While I had the wires off I also tested the two large terminals for continuity and there was none , so I hooked everything back up. No start. I found that I had a similar solenoid I removed from another vehicle, so I tried it also. Still no start.

CharleyL

If you jumpered the heavy terminals on the start relay and the motor turns over, the battery and the starter are good. If you can turn the key to start and the start relay clicks,but the motor won't turn over, the starting relay power contacts are defective and the relay needs replacing. Do you know the condition of the solenoid (relay) that you found? It may also be bad.

When you turn the key to start, the starting relay should operate (loud click). Inside the relay heavy electrical contacts connect the two heavy wires that you jumpered together, sending power from the battery through the start relay and on to the starter. The starter then turns and starts the motor. It wouldn't do this when you turned the key to start, so I had you jumper the heavy wire connections on the start relay and the starter turned the motor over. Something is wrong with your key circuit or you are imagining that you hear the start relay click. Please check these steps again. Have you checked the fuses? The one for the start circuit may be bad. If you have to replace it be sure to use an identical replacement with the same ampere rating.

Charley

namyot11

Thanks for staying with me on this Charley. The solenoid I used looks to be new. I bought it for something else years ago and never used it. I think both solenoids are good. When I turn the key to the first position I hear a click under the dash. Then when I turn it to the start position the solenoid does not click as I know it should. All the fuses are good, except one of the four is missing, but it was never there even when the cart worked. Could there be a safety start or clutch start switch somewhere in the starting circuit?

namyot11

I just found the service manual for the Cushman on Jacobsen.com. It shows a clutch safety switch. I'll have to locate the wires going to it to see if there's power.There are also wiring diagrams but I'm not sure which wiring diagram to use as there are many models shown, but not one specifically for an 898530. Any idea which model would be closest?

CharleyL

I was about to suggest looking for safety switches between the key switch and the start relay. If there is a clutch safety switch it would open this circuit. Since the starting circuits are very likely all the same or nearly the same between the different models it probably won't matter which schematic/wiring diagram you use. See if these wires are the same on the different schematics. If they are then just pick one and follow it.

The best way to check a safety switch is to temporarily bypass it with a jumper and see if the key will activate the starter. If there is more than one safety switch in the circuit more than one may be causing problems so you may need more than one jumper. Of course you can also disconnect the wires from the switch and check it with an ohmmeter to see if it's working. If you use jumpers, just be certain that the wheels aren't touching the ground and you are free of any possible hazard, just in case it should suddenly start, and also be prepared to turn the key switch off quickly if it should suddenly start. Safety switches are important and are there for a reason, so don't permanently bypass them. Lawn tractors have seat safety switches, brake safety switches, clutch safety switches, mower engaged safety switches, etc. Each machine is different. You will need to look at the schematic to see what you might have and then find each one and check it.

Look at the bright side of this. You are learning more about your Truckster so the next time you have a similar problem you will locate it much quicker.

One of us might live near you and could help. Please go to "User CP" on the left end of the dark blue bar at the top of the screen and fill in details about yourself and where you live. The town and State are good enough for the location.

Charley

namyot11

I had already located the clutch safety switch and tried to bypass it by the time I read read your response, Charley. No go. I'm frustrated but will keep on trying things. The wiring is old and faded, so it's difficult to determine the colors to follow them. I was also wondering if the ignition switch itself could be bad.