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Circuit Resistance

Ohm's law (E=IxR) tells us that even very low resistance in the starter circuit will cause the starter to turn slowly, because of low voltage. For example: in a system drawing 200 amps, 0.01 ohms resistance in the starter cable will cause a 2 volt drop in voltage at the starter; 0.01 ohms is too little for all but the most expensive and sophisticated ohmmeters to measure, but measurements of voltage drop will indicate where there is resistance.

Voltage Drop

In automotive circuits even the smallest loss of voltage will cause poor performance. Set your Fluke multimeter in the mV or VDC setting and connect the meter + lead to the side of the device nearer the battery + terminal and the - lead to the side nearer the battery - terminal or ground and engage the Min/Max function. Current must be flowing for the meter to register the voltage drop found. This procedure is helpful on components and connections (both on the + feed side and - ground side) except solenoids, which read battery voltage if you measure across them when the engine is being cranked.

Voltage drops should not exceed the following:
200 mV Wire or cable
300 mV Switch
100 mV Ground
0 mV to <50 mV Sensor Connections
0.0V Connections

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Fig 7 - Testing for Excessive Voltage Drop Determine if there is resistance in the circuit by measuring the voltage drop across each connection and component in the starter circuit while cranking the engine. Measure the voltage drop between the battery post and the connecting cable, the solenoid posts and the wires that attach to them, and across the solenoid itself. Also check the connection on the starter, alternator (feed and ground side) and the ground strap connection to the engine block and body.