321 

 

Starter can’t work 

Low voltage of battery 

Charge or replace battery 

Broken fuse of starter 

Change starter fuse 

Malfunction of starter relay 

Change starter relay 

Open circuit or poor contact of connector loop for starter 

Blocking or incapable rotating or crankshaft for 
engine 

Check and repair 
starter loop 

Check and repair 
engine 

Starter in poor operation 

Replace starter 
assembly 

Normal 

Abnormal 

Normal 

Normal 

Normal 

Normal 

Broken 

Abnormal 

Abnormal 

Broken 

Too low 

 
 

 

 

322 

 

No. 230 Idling of starter   

Malfunction Cause 

Solution 

Malfunction of electromagnetic 
switch  

Check coil poles of electromagnetic switch for short-circuit, which will result 
in idling of starter due to positive pole of power supply connecting to 
exciting coil of starter; replace electromagnetic switch or starter assembly if 
necessary;  

 
Malfunction of one-way clutch   

Check working, wearing-out and damaging condition of clutch planetary 
gear. Hold starter clutch with hand and rotate planetary gear clockwise to 
check free rotating of this gear; and try to rotate planetary gear 
counterclockwise; it should not be rotated; replace starter assembly if it’s 
abnormal;  

Malfunction of starter fastening 
bolt  

Check starter fastening bolt for loosing, which will result that one-way clutch 
can’t engage with ring gear of flywheel to drive torque and that the starter is 
idling; bolt should be tightened or replaced;   

Check ring gear of flywheel for worn-out or damage and loosing, which will 
result that torque can’t be driven through starter and that the starter is 
idling; flywheel assembly should be replaced;   

Check fastening bolt of flywheel for loosing and dropping-off; if it’s 
abnormal, it should be tightened or flywheel assembly should be replaced; 

Idling of starter   

Malfunction of flywheel   

Check the engaging gears of starter and flywheel for over worn-out or 
damaged tooth, which will result that gears can’t engage to drive torque and 
that the starter is idling; pinion of starter or starter assembly should be 
replaced;  

 

Idling of starter 

Short-circuit of internal contacts of electromagnetic 
switch for starter 

Replace electromagnetic switch or 
starter assembly

Slipping or broken tooth of starter one-way clutch 

Loosing of starter fastening bolt 

Tightening 

Damage or loosing of ring gear for starter and flywheel 

Tighten or replace 
flywheel

Replace one-way clutch 

Normal 

Abnormal 

Normal 

Normal 

Loosing

Broken

Short-circuit

 
 

 

 

323 

 

No. 231 Abnormal sound during start-up of starter   

Malfunction Cause 

Solution 

Check bearing and pinion of one-way clutch for damage, which may 
result in “breaking” between gear of one-way clutch and ring gear of 
flywheel and subsequent abnormal sound during start-up; thus one-way 
clutch should be replaced;   

Malfunction of one-way clutch 

Check if pinion of one-way clutch return well after start-up; if not, the 
pinion will contact to ring gear of flywheel after start-up and result in 
abnormal sound; one-way clutch should be dismantled for checking and 
greasing or replaced;   

Malfunction of battery   

Check if voltage of battery reaches to 12.5 – 12.9 V; if the voltage is 
over-low, starter will be unable to drive torque to flywheel and 
electromagnetic switch of starter will snap-on and generate abnormal 
sound due to no energy; thus battery should be recharged or replaced; 

Internal malfunction of starter   

Check internal bearing bush of starter for wearing condition; if it’s 
over-worn, stator and rotator of starter will contact and result in abnormal 
sound; thus starter assembly should be replaced;   

Malfunction of electromagnetic 
switch  

Check coil of electromagnetic switch for short-circuit or poor contact; if it’s 
abnormal, electromagnetic switch should be replaced;   

Abnormal sound 
during start-up of 
starter  

Malfunction of flywheel   

Check ring gear of flywheel for over worn-out or damage and loosing, 
which may result in bad engaging between one-way gear of starter and 
ring gear of flywheel for driving torque and subsequent abnormal 
“breaking” sound; thus ring gear of flywheel or flywheel assembly should 
be replaced;   

 

 

Replace one-way clutch 

Damage of one-way clutch bearing and pinion 

Abnormal sound during start-up of 
starter 

Low voltage of battery 

Recharge or replace battery 

Over worn-out of internal bearing bush for starter 

Replace starter 

Damage or loosing of ring gear for engine flywheel 

Replace 
flywheel 

Normal 

Abnormal 

Normal 

Normal 

Abnormal 

Over-low

Broken

 
 

 

 

324 

 

No. 232 Over-high or over-low recharging voltage from generator   

Malfunction Cause 

Solution 

 

Malfunction of generator 
belt  

Check generator belt for tension and wearing condition and if there is 10 mm of 
flexibility at middle of belt under 50 N pressure; if the belt is over-loosing or 
over worn-out, the generator belt should be adjusted or replaced;   

Malfunction of fuse   

Check fuse of generator (60A) for poor contact; if it’s broken, the generator 
fuse should be replaced;   

Poor contact of harness 

Check and remove fault of bad wire contact;   

Malfunction of generator 
regulator  

Check if generator regulator is able to adjust generated voltage; if it’s 
abnormal, regulator or generator assembly should be replaced;   

1. Check forward rectifying: Connect one probe of Ohm meter to positive pole 
of rectifying diode, and the other probe to every end of rectifiers; changeover 
the polarity of probes and repeat above procedure; the Ohm meter will show 
conducting for one and cutoff for the other; if the conductivity is different from 
above description, the rectifier or generator assembly should be replaced;   

Malfunction of generator 
rectifier  

2. Check backward rectifying: Connect one probe of Ohm meter to negative 
pole of rectifying diode, and the other probe to every end of rectifiers; 
changeover the polarity of probes and repeat above procedure; the Ohm meter 
will show conducting for one and cutoff for the other; if the conductivity is 
different from above description, the rectifier or generator assembly should be 
replaced.  

Over-high or 
over-low recharging 
voltage from 
generator  

Malfunction of battery   

Check internal plate of battery for sulfurization or short-circuit, which may result 
in over recharging current and subsequent over recharging energy from 
generator, thus the battery should be replaced;