Troubleshooting - Suzuki DF 90 Service Manual

TROUBLESHOOTING

NOTE:
Before troubleshooting the electric starter system, make sure of the following :
• Battery is fully charged.
• All cables / wires are securely connected.
• Shift is in "NEUTRAL" position.
If any abnormality is found, immediately disconnect battery cables from battery.
Engine does not start.
Does engine turn over
with continued cranking?
YES
Does the flywheel rotate?
No (or turns slowly)
• Check battery for charg-
ing condition.
• Check battery terminals
for connections and cor-
rosion.
NO
Does starter motor ro-
tate?
• Check battery for charg-
ing condition.
• Check battery terminals
for connections and cor-
rosion.
• Check main (60A) and /
or sub (30A) fuse / case.
(See page 4-3)
YES
Check for starter relay
"Click" sound when turn-
ing ignition switch to
"START".
Is there "Click" sound?
• Check pinion and over-
running clutch. (See
page 4-18)
• Check starter magnetic
switch. (See page 4-20)
• Remove starter motor
from engine.
• Does starter motor turn
under no-load condi-
tions by connecting bat-
tery + terminal to "M"
terminal of starter motor
and battery - terminal
to the star ter motor
body.
• The magnetic switch
and / or connection is
faulty.
Replace it.
NO
YES
• Check function of neu-
tral switch. (See page 4-
11)
NO
• Check ignition switch
function. (See page 4-
10)
• Check starter relay. (See
page 4-10)
• Check wiring system
and connections be-
tween starter relay and
YES
ignition switch.
• Check the brush and
brush holder. (See page
NO
4-17)
• Check the armature coil.
(See page 4-17)
YES
ELECTRICAL 4-9