Note: Before you start, see Chapter 3.
Examination
1. If the starter does not turn the crankshaft - this is not a problem, there are several possible reasons:
- a) Bad battery
- b) Poor electrical contact between the switch, the battery terminal on the traction relay and the starter to transfer the required current from the battery to the starter to ground
- c) Faulty traction relay switch
- d) Mechanical or electrical damage to the starter
- e) Starter gear and/or flywheel ring gear badly worn and need to be replaced
2. To check the battery, just turn on the headlights. If they dim after a few seconds, the battery is dead. If the bulbs are bright, turn on the starter switch and watch what happens to the headlight bulbs. If they dim, then the energy reaches the motor, but it does not turn.
If the starter turns slowly, continue the test as follows.
3. If the headlights do not dim when the starter switch is activated, there is not enough power being supplied to the starter motor.
Disconnect the battery and starter/traction relay power wires and engine ground strap, then thoroughly clean and reinstall.
Lubricate the battery connections with petroleum jelly to prevent corrosion. Corroded connections are the most common cause of electrical failures in a system.
4. If checking and cleaning fail, listen for a click when the starter switch is activated. This indicates that the traction relay switch is activated, but does not close the main contacts, which means that the traction relay is faulty.
The traction relay can be tested by connecting a voltmeter between the main connection terminal on the traction relay and ground. When the switch is activated, the voltmeter should indicate battery voltage. If not, the traction relay unit is defective and must be replaced.
5. If the starter runs but does not turn the crankshaft, the starter gear and/or flywheel ring gear is probably worn out. In this case, the starter will make noise during operation.
6. Finally, if it is established that the traction relay is in order and 12 volts are supplied to the starter, the motor itself is faulty, and it must be removed for inspection.
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