Electrical System 5) TROUBLE SHOOTING FOR STARTER MOTOR
SERVICE RECOMMENDATIONS : The failure of the engine to start may be attributed not only to starter but also to other system. Before dismantling Starter Motor from engine, make sure that Starter Motor is faulty. Below trouble shooting chart will help on diagnosing the fault. It is recommended to replace complete Starter Motor for any internal failure of Starter Motor. Not to disassemble the Starter Motor for repairing inside components. TROUBLE
PROBABLE CAUSE
(A) Starter does not starts the engine.
1. Check the Ignition key switch. 2. Check the battery condition. 3. Check the proper connection of battery terminal. 4. Defective Starter Motor.
REMEDY 1. Replace Ignition key switch. 2. Substitute a fully charged battery. 3. Clean the battery terminal and apply petroleum jelly on terminal & tight all connection 4. Replace the Starter Motor.
(B) Starter crank but engine does not fire.
1. Check the battery condition. 2. Check the fuel flow. 3. Remove the Starter Motor & check.
1. Substitute a fully charged battery. 2. Ensure fuel flow. 3. Check the starter if found defective replace the starter motor.
(C) Starter works but pinion fails to engage.
1. 2. 3. 4.
1. Replace starter motor.
(D) Starter continuous to run after switch is released
1. Sticky starting switch. 2. Sticky solenoid switch contact. 3. Pinion/Ring Gear folded or damaged. 4. Sticky Drive Assembly
1. Disconnect Starter cable immediately with battery & replace starter switch 2. Replace Starter motor. 3. Replace Starter motor. 4. Replace Starter motor.
(E) Pinion engages with Ring Gear but the engine is not cranked
1. Clutch (Drive Assembly) Slip. 2. Starter switch defective. 3. Check the battery condition.
1. Replace the Starter motor 2. Repair or replace starter switch. 3. Replace with charged battery.
Pinion sticky on shaft. Burr on pinion / ring gear. Lever defective. Bushes worn out.
Table No. 1
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
G-23
