1I
Cranking System Symptom Diagnosis
Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies.....in battery, wiring harness, (including starting motor switch), starting motor control relay (for K9K Engine), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor
For M13 Engine
Condition Possible Cause Action
Motor not running (No operating sound of magnetic switch)
Shift lever switch is not in P or N, or not adjusted (A/T)
Shift in P or N, or adjust switch.
Battery run down
Recharge battery.
Battery voltage too low due to battery deterioration
Replace battery.
Poor contact in battery terminal connection
Retighten or replace.
Loose grounding cable connection
Retighten.
Fuse set loose or blown off
Tighten or replace.
Poor contacting action of ignition switch and magnetic switch
Replace.
Lead wire coupler loose in place
Retighten.
Open-circuit between ignition switch and magnetic switch
Repair.
Open-circuit in pull-in coil
Replace magnetic switch.
Brushes are seating poorly or worn down
Repair or replace.
Poor sliding of plunger and/or pinion
Repair.
Motor not running (Operating sound of magnetic switch heard)
Battery run down
Recharge battery.
Battery voltage too low due to battery deterioration
Replace battery.
Loose battery cable connections
Retighten.
Burnt main contact point, or poor contacting action of magnetic switch
Replace magnetic switch.
Brushes are seating poorly or worn down
Repair or replace.
Weakened brush spring
Replace.
Burnt commutator
Replace armature.
Layer short-circuit of armature
Replace.
Crankshaft rotation obstructed
Repair.
Starting motor running but too slow (small torque) (If battery and wiring are satisfactory, inspect starting motor)
Insufficient contact of magnetic switch main contacts
Replace magnetic switch.
Layer short-circuit of armature
Replace.
Disconnected, burnt or worn commutator
Repair commutator or replace armature.
Worn brushes
Replace brush.
Weakened brush springs
Replace spring.
Burnt or abnormally worn end bush
Replace bush.
Starting motor running, but not cranking engine
Worn pinion tip
Replace over-running clutch.
Poor sliding of over-running clutch
Repair.
Over-running clutch slipping
Replace over-running clutch.
Worn teeth of ring gear
Replace flywheel (M/T) or drive plate (A/T).
Noise
Abnormally worn bush
Replace bush.
Worn pinion or worn teeth of ring gear
Replace pinion or flywheel (M/T) or drive plate (A/T).
Poor sliding of pinion (failure in return movement)
Repair or replace.
Worn internal or planetary gear teeth
Replace.
Lack of oil in each part
Lubricate.
Starting motor does not stop running
Fused contact points of magnetic switch
Replace magnetic switch.
Short-circuit between turns of magnetic switch coil (layer short-circuit)
Replace magnetic switch.
Failure of returning action in ignition switch
Replace.

For K9K Engine
Condition Possible Cause Action
Motor not running (No operating sound of magnetic switch)
Battery run down
Recharge battery.
Battery voltage too low due to battery deterioration
Replace battery.
Poor contact in battery terminal connection
Retighten or replace.
Loose grounding cable connection
Retighten.
Fuse set loose or blown off
Tighten or replace.
Poor contacting action of ignition switch and magnetic switch
Replace.
Lead wire coupler loose in place
Retighten.
Open-circuit between ignition switch and magnetic switch
Repair.
Open-circuit in pull-in coil
Replace starting motor.
Brushes are seating poorly or worn down
Replace starting motor.
Poor sliding of plunger and/or pinion
Replace starting motor.
Faulty starting motor control relay
Replace.
Motor not running (Operating sound of magnetic switch heard)
Battery run down
Recharge battery.
Battery voltage too low due to battery deterioration
Replace battery.
Loose battery cable connections
Retighten.
Burnt main contact point, or poor contacting action of magnetic switch
Replace starting motor.
Brushes are seating poorly or worn down
Replace starting motor.
Weakened brush spring
Replace starting motor.
Burnt commutator
Replace starting motor.
Layer short-circuit of armature
Replace starting motor.
Crankshaft rotation obstructed
Repair.
Starting motor running but too slow (small torque) (If battery and wiring are satisfactory, inspect starting motor)
Insufficient contact of magnetic switch main contacts
Replace starting motor.
Layer short-circuit of armature
Replace starting motor.
Disconnected, burnt or worn commutator
Replace starting motor.
Worn brushes
Replace starting motor.
Weakened brush springs
Replace starting motor.
Burnt or abnormally worn end bush
Replace starting motor.
Starting motor running, but not cranking engine
Worn pinion tip
Replace starting motor.
Poor sliding of over-running clutch
Replace starting motor.
Over-running clutch slipping
Replace starting motor.
Worn teeth of ring gear
Replace flywheel.
Noise
Abnormally worn bush
Replace starting motor.
Worn pinion or worn teeth of ring gear
Replace starting motor or flywheel.
Poor sliding of pinion (failure in return movement)
Replace starting motor.
Worn internal or planetary gear teeth
Replace starting motor.
Lack of oil in each part
Replace starting motor.
Starting motor does not stop running
Fused contact points of magnetic switch
Replace starting motor.
Short-circuit between turns of magnetic switch coil (layer short-circuit)
Replace starting motor.
Failure of returning action in ignition switch
Replace.