59
COMPLAINT
STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION
1.4.1 Adjust continuity range on a multimeter.
Connect the multimeter across the neutral switch
with one probe on the switch terminal (black
wire) and the other probe on the gear shifter.
If continuity is not observed then it indicates that
the neutral switch may be faulty. Take the
following steps.
1.4.2 Remove the neutral switch from the Gear
shifter housing. Check whether there is any oil
layer on the plunger of the switch. Clean it and
again check for continuity. If there is no continuity
then the neutral switch is faulty. Replace the
same.
1.4.3 If continuity is observed then check
whether the plunger of the switch has got
compressed and as such is not making contact
with the Gear Shifter. In that case also replace
the switch.
Substitute with a fully charged battery. If the
starter now cranks the engine, then the battery
must be attended to.
Repair / Replace relay.
Clean the terminal and smear petroleum jelly.
Tighten all connections.
Replace brushes, if found to be wornout.
Remove dirt or oil. If commutator is burnt,
replace armature.
Replace bush bearing.
Replace armature.
Lubricate pinion and shaft helix with light oil.
Deburr by filing and clean up.
Remove the starter from the vehicle and replace
drive assly., test and refit the starter.
Tap on bush button switch to release if not
disconnect battery.
Disconnect battery, repair or replace relay.
Remove the starter from the vehicle and replace
bush.
Clean thoroughly deburring pinion & ring gear by
filing.
1.4 Neutral switch checking.
a)
Discharged battery / Defective
battery
b)
Relay drop high.
c)
Loose or oxidized battery terminals/
corroded or loose defective earth
connections.
d)
Brushes wornout and not making
proper contact with commutator.
e)
Dirty, oily or badly burnt commutator
f)
Bush worn out.
g)
Armature defective.
a)
Pinion movement sticky.
b)
Heavily burred pinion or ring gear.
Drive slip
a)
Sticky push button switch.
b)
Sticky relay
c)
Bush in pinion seized on shaft.
d)
Pinion/Ring gear fouled or
damaged.
Armature fails to
rotate or rotates
slowly and the starter
does not crank the
engine though pinion
has engaged with
ring gear.
Armature rotates but
pinion fails to engage.
Armature rotates,
pinion engages with
the ring gear but the
engine is not cranked.
(A whining noise is
heard).
Starter continues to
run after the switch is
released.
Summary of Contents for Legend 00300728
Page 1: ...Service Station Manual Service Station Manual USA MODEL NO 00300728...
Page 26: ...22...
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