1. STARTER SYSTEM DIAGNOSIS AND SERVICE
CHAPTER 5
LAB MANUAL

2. STARTING SYSTEM COMPONENTS
BATTERY
CABLES AND WIRING
IGNITION SWITCH
NEUTRAL SAFETY SWITCH
STARTER RELAY/SOLENOID
STARTER MOTOR
LAB 155

3. TROUBLESHOOTING FOUR CATEGORIES NO CRANK SLOW CRANK SPINS BUT NO CRANK
EXCESSIVE NOISE
LAB 156

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
LAB

6. QUICK TEST TURN HEADLIGHTS ON CRANK ENGINE NOTE RESULTS
DON’T OVERCRANK ENGINE
LAB 161

7. CURRENT DRAW TEST DISABLE IGN. VISUAL INSPECT HOOK UP EQUIPMENT
TURN OFF ALL ELECTRICAL LOADS
PERFORM TEST
LAB 162

8. INSULATED CIRCUIT RESISTANCE TEST
VOLTMETER ON LOW SCALE
HOOK UP EQUIPMENT
CRANK ENGINE
NOTE VOLTAGE
LESS THAN VOLT
LAB 164

9. GROUND CIRCUIT RESISTANCE TEST
SELECT LOW SCALE
HOOK UP EQUIPMENT
CRANK ENGINE
NOTE RESULTS
LESS THAN 0.2V
LAB 165

10. SOLENOID CIRCUIT TEST DISABLE IGN. LOW VOLT SCALE
CONNECT ACROSS SOLENOID
CRANK ENGINE
VOLTAGE LESS THAN 0.1 VOLT
LAB 166

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

12. STARTER R & R DISCONNECT BATTERY! IDENTIFY WIRES
PAY ATTENTION TO SHIMS, ETC.
ADJUST DRIVE GEAR CLEARANCE
RE-CK OPERATION
LAB 170

13. THE END