1. Starter does not work

(1) Fault phenomenon: Turn the ignition switch to the start position, the starter does not work, and there is no starting sound.

(2) Fault cause

① Power supply failure: such as poor contact between the battery pole and the wire clamp, loose or poor contact of the starter circuit wire, battery power loss, plate sulfation or short circuit, etc.

② Starter failure: wear and burn of the commutator and brushes causing poor contact; burn of the electromagnetic switch contact plate and main contact causing poor contact; electromagnetic switch attraction and holding coil open circuit, etc.

③ Starter relay failure: such as open circuit, short circuit, poor contact of the starter relay coil, etc.

④ Ignition switch failure: such as loose ignition switch wiring, internal contact damage, etc.

⑤ Starter circuit failure: such as blown fuse, open circuit in the starter system circuit, etc.

(3) Fault diagnosis and troubleshooting methods

① Press the horn and turn on the high beam. If the horn sound is low and the high beam is dim, it means there is a power supply failure. Focus on checking the battery's positive and negative terminals and the cables connecting the starter motor for looseness and proper contact. Feel the wire connections for heat. If any heat or loose contact is detected, reconnect them securely. If all of the above checks are correct, check the battery capacity and internal faults.

       ② If the power supply is normal, use a screwdriver to connect the battery terminal and the motor terminal on the starter solenoid switch. If the starter motor does not rotate, there is an internal fault in the starter motor and the starter should be disassembled and inspected. If the starter motor idles normally, proceed to the next inspection.

③ Use a screwdriver to connect the battery terminal and the relay terminal on the starter solenoid switch. If the solenoid switch does not activate, or if the solenoid switch activates but the starter motor does not activate, there is an internal fault in the solenoid switch and the solenoid switch should be disassembled and inspected or replaced. If the solenoid switch is operating normally and the starter motor operates normally, proceed to the next inspection.

④ Use the DC voltage setting on a multimeter to check if the voltage between the starter relay's B terminal and ground is approximately 12.5V. If there is no voltage or very low voltage, there is a fault in the wiring between the starter relay's B terminal and the battery's positive terminal. This should be checked and corrected. If the voltage is normal, connect the starter relay's B terminal and S terminal with a thick wire. If the starter fails to start, there is a fault in the wiring between the starter relay's S terminal and the starter solenoid switch relay terminal. This should be checked and corrected. If the starter starts and runs normally, proceed to the next step.

⑤ Use a thick wire to connect the starter relay's B terminal and SW terminal. If the starter fails to start, there is a fault in the starter relay and the starter relay should be replaced. If the starter runs normally, check the wiring between the starter relay's SW terminal and the battery for a fault. If the wiring is normal, there is a fault in the ignition switch and it should be repaired or replaced.

2. The starter is weak

(1) Fault phenomenon When the starter is started, the drive gear can engage with the flywheel ring gear, but the starter speed is obviously low or even stops.
(2) Fault cause
① Power failure; battery power is low or the plate is vulcanized or short-circuited, the starting power supply wire connection is poor, etc.
② Starter failure: poor contact of the starter electromagnetic switch, poor contact between the commutator and the brush, local short circuit of the field winding or armature winding, etc.
(3) Fault diagnosis and troubleshooting methods

① Check the battery capacity and the connection wire between the battery and the starter.

② When the battery capacity is sufficient and the connection wire between the battery and the starter is normal, use a screwdriver to connect the "battery terminal" and "motor terminal" on the starter electromagnetic switch. If the starter runs strongly, it means that the main contact and contact plate in the electromagnetic switch are in poor contact, and the electromagnetic switch should be repaired or replaced; if the starter still runs weakly, it means that there is a fault inside the starter, and the starter should be disassembled and inspected.

3. Starter idling

(1) Fault phenomenon: The starter idles during startup, but the engine does not rotate.
(2) Fault cause: The one-way clutch in the starter slips and the flywheel ring gear is damaged.
(3) Fault diagnosis and troubleshooting
① When the starter is idling, there is a slight friction sound. The starter drive gear cannot engage with the flywheel teeth and idling occurs. That is, the electromagnetic switch is turned on in advance before the drive gear is engaged with the flywheel ring gear. This indicates that the electromagnetic switch contact plate movement stroke is too short. The starter should be removed and the starter connection time should be adjusted; or the ring gear on the flywheel is slipping on the flywheel.
② When the starter is idling, there is a serious sound of rubbing against the gear teeth. This indicates that the flywheel teeth or the drive gear are slipping due to severe wear. The starter should be removed for further inspection and the flywheel ring gear or drive gear should be replaced as appropriate.
③ When the starter is idling, the speed is fast and there is no sound of gear collision, which means that the drive gear has engaged with the flywheel ring gear, but cannot drive the flywheel to rotate. The starter is just idling. This is caused by the slippage of the starter's one-way clutch. The one-way clutch assembly should be replaced.