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2.11.5 Diagnostic information and procedures 

2.11.5.1 Diagnosis descriptions 

See 2.11.2.2 Description and Operations of Starter System. Start system diagnosis after getting to 
be familiar with the system functions and operations. This helps the identification of malfunctions 
in case of malfunctions. 

Breaking step, what's more, it is conducive to determining whether the condition described by the 
customer belongs to the normal operation. 

2.11.5.2 Visual Inspection 

1.  Inspect whether there is after-sales optional device which will affect start, charing or 

operation of ignition system. 

2.  Inspect the easy to access system components to identify whether there is obviously damage 

or potential fault. 

3.  Inspect whether the battery is installed correctly. 

4.  Test battery status. Battery voltage is not less than 11V. 

5.  Inspect whether there is wire damage. Inspect starter motor, starter solenoid switches, 

ignition switches and battery. Inspect whether all ground connections are reliable. 

6.  If the battery, wires and switches are normal, and engine functions are normal, dismantle and 

test the starter motor. 

7.  When the charging system works properly, turn the ignition switch to "ON" position, the 

charge indicator lamp will be on. The lamp will be off after the engine starts running. 

8.  Inspect whether the generator is loose or improperly installed, as well as the drive belt 

tension is normal, whether there is the possibility of slipping. 

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2.11.5.3 Starting Motor Noise Diagnostic 

Before the diagnosis, please refer to the 2.11.2.1 Battery Description and Operation, 2.11.2.2 Start 
System Description and Operation and 2.11.2.1 Charging System Description and Operation, and 
perform the necessary inspection. 

1 

Start the engine, while monitoring whether the starter motor starts turning. 

When the engine started and the starter remained at the bonding position, whether there is loud 
"breathing" (If the starter remains in bonding position and further increases the engine speed, the 
sound may sound as an alarm)? 

 

2 

After starting the engine, during gradually stopping the starter, is there any "rumble", 
"roar" or in some cases "percussion sound "? 

 

 

4 

Remove the starter motor. 

Inspect starter motor shaft housing and clutch gear. If the clutch gear or shaft housing has cracking 
or wear? 

 

5 

Replace the flywheels. 

 

3 

During the startup of the engine and after normal startup with the crankshaft running, 
is there any high-frequency hum sound? 

6 Troubleshooting 

Next 

Yes 

Refer to 2.12.6.4 “Replacement of Starter” 
to replace the starter. 

No 

Yes 

Refer to 2.12.6.4 “Replacement of Starter” 
to replace the starter. 

No 

Yes 

Inspect the flywheel ring gear for 
existence of the following: tooth cracking, 
tooth loss, tooth wear, flywheel bent or the 
tooth damage, if necessary, replace the 
flywheel. 

No 

Yes 

Go to step 4 

No 

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2.11.5.4 Generator Noise Diagnosis 

Diagnostic Hints: Generator noise may be caused by electrical or mechanical noise. Electrical 
noise (electromagnetic hum sound) is usually added to the generator with the electrical load 
changes, which is the normal operating characteristics of all generators. During the service, pay 
attention to distinguishing, otherwise it will cause unnecessary customer complaints. When 
diagnosing the mechanical noise of generator, firstly inspect whether there are loose generator 
components or interference. In some cases even if the sound in engine compartment is light, it can 
enter the passenger compartment. If this is the case, replacing the generator does not solve the 
problem, which leads to misjudgments. 

1 

Stop the generator, and confirm whether the noise disappears. 

A.  Start the engine, verify that the noise can be heard. 

B.  Shut down the engine. 

C.  Disconnect the generator harness connector EM07 from the generator. 

D. Start 

the 

engine. 

Confirm whether the noise disappears? 

 

2 

Inspect the generator shaft. 

1.  Shut down the engine. 

2.  Dismantle the drive belt. 

3.  Rotate the generator pulley by hand. 

Does the generator rotate smoothly without catching and grinding noise? 

 

Dismantle and install the generator again. Tighten the mounting bolts of generator to the specified 
torque. Refer to 2.12.6.3 Replacement of Generator 

Start the engine, does the noise disappear? 

 

4 

Inspect whether the drive belt is loosened. 

 

3 Reinstall 

the 

generator. 

Yes 

Go to step 7 

No 

Yes 

The system is normal. 

No 

Yes 

Go to step 6 

No 

Yes 

Go to step 6 

No 

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