G-23
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
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.
Table No. 1
TROUBLE PROBABLE CAUSE REMEDY
(A) Starter does 1. Check the Ignition key switch. 1. Replace Ignition key switch.
not starts the 2. Check the battery condition. 2. Substitute a fully charged battery.
engine. 3. Check the proper connection 3. Clean the battery terminal and
of battery terminal. apply petroleum jelly on terminal
& tight all connection
4. Defective Starter Motor. 4. Replace the Starter Motor.
(B) Starter crank 1. Check the battery condition. 1. Substitute a fully charged battery.
but engine 2. Check the fuel flow. 2. Ensure fuel flow.
does not fire. 3. Remove the Starter Motor & 3. Check the starter if found
check. defective replace the
starter motor.
(C) Starter works 1. Pinion sticky on shaft. 1. Replace starter motor.
but pinion fails 2. Burr on pinion / ring gear.
to engage. 3. Lever defective.
4. Bushes worn out.
(D) Starter 1. Sticky starting switch. 1. Disconnect Starter cable
continuous to 2. Sticky solenoid switch contact. immediately with battery & replace
run after switch 3. Pinion/Ring Gear folded or starter switch
is released damaged. 2. Replace Starter motor.
4. Sticky Drive Assembly 3. Replace Starter motor.
4. Replace Starter motor.
(E) Pinion engages 1. Clutch (Drive Assembly) Slip. 1. Replace the Starter motor
with Ring Gear 2. Starter switch defective. 2. Repair or replace starter switch.
but the engine 3. Check the battery condition. 3. Replace with charged battery.
is not cranked
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