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Comprehensive Starter System Troubleshooting Guide

Learn how to diagnose and service starting system components like battery, ignition switch, and more. Follow procedures and trouble charts for no crank, slow crank, spins but no crank issues. Test equipment accurately for quick diagnosis. Be cautious and follow the troubleshooting steps provided to ensure proper diagnosis and repair of starter system issues.

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Comprehensive Starter System Troubleshooting Guide

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  1. STARTER SYSTEM DIAGNOSIS AND SERVICE

  2. STARTING SYSTEM COMPONENTS • BATTERY • CABLES AND WIRING • IGNITION SWITCH • NEUTRAL SAFETY SWITCH • STARTER RELAY/SOLENOID • STARTER MOTOR

  3. TROUBLESHOOTING • FOUR CATEGORIES • NO CRANK • SLOW CRANK • SPINS BUT NO CRANK • EXCESSIVE NOISE

  4. PROCEDURES • CONSISTENT METHOD • VISUAL INSPECTION • BATTERY PERFORMANCE • VERIFY ENGINE CONDITION IF NO CRANK OR SLOW CRANK • (BE CAUTIOUS)

  5. TROUBLE CHARTS • FIND NORMAL AMPERAGE STARTER DRAW SPECS. • BY SYMPTOM, CAN SOMETIMES DIAGNOSE PROBLEM IN STARTING SYSTEM • TESTING EQUIPMENT MUST BE ACCURATE

  6. QUICK TEST • TURN HEADLIGHTS ON • CRANK ENGINE • NOTE RESULTS • DON’T OVERCRANK ENGINE

  7. CURRENT DRAW TEST • DISABLE IGN. • VISUAL INSPECT • HOOK UP EQUIPMENT • TURN OFF ALL ELECTRICAL LOADS • PERFORM TEST

  8. INSULATED CIRCUIT RESISTANCE TEST • VOLTMETER ON LOW SCALE • HOOK UP EQUIPMENT • CRANK ENGINE • NOTE VOLTAGE • LESS THAN 0.2 VOLT

  9. GROUND CIRCUIT RESISTANCE TEST • SELECT LOW SCALE • HOOK UP EQUIPMENT • CRANK ENGINE • NOTE RESULTS • LESS THAN 0.2V

  10. SOLENOID CIRCUIT TEST • DISABLE IGN. • LOW VOLT SCALE • CONNECT ACROSS SOLENOID • CRANK ENGINE • VOLTAGE LESS THAN 0.1 VOLT

  11. FREE SPEED TEST • TESTS STARTER FREE LOAD • AMPS • RPM • CAUTION! • COMPARE RESULTS TO SPECS

  12. STARTER R & R • DISCONNECT BATTERY! • IDENTIFY WIRES • PAY ATTENTION TO SHIMS, ETC. • ADJUST DRIVE GEAR CLEARANCE • RE-CK OPERATION

  13. THE END

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