Section 12 ELECTRICAL SYSTEM
Subsection 04 (STARTING SYSTEM)
SMR2003-037_12_04A.FM 12-04-5
STARTING SYSTEM TROUBLESHOOTING
SYMPTOM CAUSE REMEDY
STARTER DOES NOT TURN. Burnt fuse (see text above). Check wiring condition and replace fuse.
Poor contact of battery terminal(s). Clean and tighten terminal(s).
Poor battery ground cable connection. Clean and tighten.
Weak battery. Recharge or replace battery.
Poor contact of start/stop switch,
safety lanyard switch or solenoid.
Check connectors and clean contacts.
Check and replace defective parts.
Open circuit: start/stop switch or
solenoid.
Check and replace.
Safety lanyard or MPEM (or EMS ECU
on 4-TEC engines).
Refer to DIGITALLY ENCODED
SECURITY SYSTEM
or ENGINE
MANAGEMENT
.
DESS auxilliary module (if so
equipped on 4-TEC engines)
Refer to
ENGINE MANAGEMENT.
STARTER ENGAGES;
BUT DOES NOT CRANK
THE ENGINE.
Poor battery cable connections. Clean battery cable connections.
Poor contact of brush. Straighten commutator and brush.
Burnt commutator. Turn commutator on a lathe.
Worn commutator segments. Undercut mica.
Shorted armature. Repair or replace armature.
Weak brush spring tension. Replace brush holder or spring.
Weak magnet. Replace yoke assembly.
Worn bushings. Replace clutch.
Weak battery. Recharge or replace battery.
STARTER TURNS, BUT
OVERRUNNING CLUTCH
PINION DOES NOT MESH
WITH RING GEAR.
Worn clutch pinion gear. Replace clutch.
Defective clutch. Replace clutch.
Poor movement of clutch on splines. Clean and correct.
Worn clutch bushing. Replace clutch.
Worn ring gear. Replace ring gear.
STARTER MOTOR KEEPS
RUNNING.
Shorted solenoid winding. Replace solenoid.
Melted solenoid contacts. Replace solenoid.
Sticking or defective starter clutch. Lubricate or replace.
Presence of salt water in the electrical
box (if so equipped) which gives
continuity.
Verify electrical box watertightness.
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