KYMCO DINK 200i Service Manual page 51

1. GENERAL INFORMATION
STARTER MOTOR
1. Starter motor won't turn
Inspection/Adjustment
Check operation of
brake light switch by
applying brake
Check battery circuit
by operating turn
signals
Check operation of
starter relay by
depressing starter
button
Connect starter
motor directly to
battery
2. Starter motor turns slowly or idles
Inspection/Adjustment
Check battery circuit
by operating turn
signals
Connect starter
motor directly to
battery
Rotate crankshaft
3. Starter motor does not stop turning
Inspection/Adjustment
Turn ignition switch
OFF
Symptom
Stoplight comes on
Signals operate
properly
Relay operates
properly
Starter motor turns
Symptom
Signals operate
properly
Starter motor
turns slowly
Turns easily
Symptom
Not stopped
Stoplight does not
come on
Signals dim, remain
on or don't operate
Relay does not
operate
Starter does not turn
Signals dim, remain
on or don't operate
Starter motor
turns normally
Hard to turn
Stopped
DINK 200i/125
Probable Cause
cBurned out fuse
dWeak or dead battery
eFaulty stop switch
fLoose or disconnected connectors
gBroken or shorted ignition switch
wire
cFaulty or weak battery
cPoor starter button connection
dOpen or shorted starter relay
eLoose or disconnected connectors
cWorn brushes
dOpen or shorted wires or rotor
eOpen starter motor cable
fLoose connectors
cOpen wire harness
Probable Cause
cWeak or dead battery
cLoose connector or terminal
dPoor contact in starter relay
eFaulty starter clutch
cSeized cylinder
cBroken or shorted starter motor
cable
Probable Cause
cFaulty starter pinion
cStarter relay shorted or stuck
closed
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