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Wheelhorse Toro 616-Z Onan will not crank

Discussion in 'Mechanic and Repair' started by 1966vette, Aug 13, 2011.

  1. 1966vette

    1966vette LawnSite Member
    Messages: 209

    Model P216V-I / 10873A
    Type #: 616-Z Hydrostatic / Y1-160E1
    Code#: C893532654

    I have a Wheelhorse Toro 616-Z that will not start!:dizzy:
    I resolved an oil leak, took it for a test run, cut 300 feet of grass & it was running fine.
    Installed a new seat & now it will not turn over!:hammerhead:

    This is what I have done so far:

    1. Battery has 12.45 Volts w/ clean battery terminal & connections

    2. All fuses checked OK w/ ohm meter

    3. Seat switch checked OK w/ ohm meter – I manually press seat switch & it will not start

    4. Parking brake switch is up on – when starting - checked OK w/ ohm meter

    5. Cleaned ignition switch – one terminal was rusty but now clean & it will not start.

    6. PTO switch is OFF when starting & clicks when activated indicating it is OK?

    7. Zero voltage to the blue wire that goes to the starter solenoid when attempting to start the engine.:nono:

    Where do I go from here?:confused:
    Thanks for helping!
  2. Restrorob

    Restrorob LawnSite Fanatic
    Messages: 11,029

    AAANNND ???

    A rusted post on a ignition switch ('B' post) is a sign of heat which with the rust causes a bad/burnt connection, This can cause the internal contacts to corrode/rust or pit.

    Test for battery voltage on the 'S' (start) post on the back of the switch, If no voltage replace the switch. If you do have voltage at the switch inspect/trace the wire back to the starter looking for breaks, I'm too lazy to look your unit up right now but some have a start relay between the switch and starter that may have failed.....
  3. dutch1

    dutch1 LawnSite Silver Member
    from Jayhawk
    Messages: 2,248


    Here's a link to your Wheel Horse. Although I didn't scout around too much, I didn't see a wiring diagram. The starter is equipped with an onboard solenoid. Right off the top of my head, I'd say you have a switch problem if you're not getting power to the solenoid when the switch is turned to the start position--and this is assuming all OPC switches are operational.

    Make sure that the seat is actually activating the seat switch.

    OH-OH. I see Rob beat me to the gravy again.
    Last edited: Aug 13, 2011
  4. dutch1

    dutch1 LawnSite Silver Member
    from Jayhawk
    Messages: 2,248

    Yeah, Rob, it does have a relay and I would assume it is part of the start circuit.
  5. 1966vette

    1966vette LawnSite Member
    Messages: 209


    Thanks for helping!
    I removed the starter relay & measured 0 voltage at the terminal that goes to the starter.
    I then removed at cleaned the PTO switch terminals – it could hear it clicking but cleaned them anyway.
    Tested the system & the starter relay started working again!

    I mowed for an hour & ZTR worked fine!
    No oil leaks & starts / stops on command.:rolleyes:

    Thanks again for all your help!
    It is very much appreciated.:drinkup:
  6. 1966vette

    1966vette LawnSite Member
    Messages: 209

    Model P216V-I / 10873A
    Type #: 616-Z Hydrostatic / Y1-160E1
    Code#: C893532654

    This unit refused to start last weekend & I tracked to down to a:
    1. bad connection at the “VR” voltage regulator
    2. bad voltage regulator
    Problem: The (3) spade clips that fasten the wires to the VR were loose –
    Solution: Clean & tighten original spare clips
    Results: still will not start

    Problem: dirty terminals on VR
    Solution: Cleaned terminals
    Results: still will not start

    I then discovered that if I pushed on all (3) spade clips & turn the key the engine always start.
    I believe in using stock wire & connections as long as possible.
    They should only be replaced as a last resort because the replacement connections are not as good as the original.

    Here are my questions:
    How do I determine if the VR is the cause of my problem or the wire terminals?
    The (3) terminals located on the VR appear to be loose!! :confused:
    Is this normal? :nono:
    Can they be tightened?:confused:
    How can I test the VR?


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