Troubleshooting

Starter motor will not turn

■ Check for blown out main or sub fuses before servicing. • Make sure the battery is fully charged and in good condrtion.

The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any other position with the side stand up and the clutch lever pulled in.

Normal

Faulty side stand switch Burnt bulb

Open circuit in wire harness Faulty clutch switch

Faulty side stand switch

Open circuit in wire harness Loose or poor contact of connector

Starter motor turns slowly

■ Low specific gravity in battery (or dead battery)

■ Poorly connected battery terminal cable

■ Poorly connected starter motor cable

■ Faulty starter motor

• Poorly connected battery ground cable

Starter motor turns, but engine does not turn

■ Starter motor is running backwards -Case assembled improperly -Terminals connected improperly

• Faulty starter clutch

• Damaged or faulty starter pinion - Damaged reduction gears

Starter relay switch "clicks", but engine does not turn over

• Crankshaft does not turn due to engine problems

* Excessive reduction gear friction

Starter Motor Removal/Installation

Awarning

• Turn the ignition switch OFF before removing the starter motor or cables.

Requisite Service

■ Fuel tank removal/installation (page 2-11)

Procedure

Q'ty

Remarks

Removal Order

Installation is in the reverse order of removal.

(1)

Starter motor cable

1

(2)

Starter motor mounting bolt

2

13)

Ground cable

1

14)

Clamp

1

<5)

Starter motor

1

(6)

O-ring

1

Starter Motor Disassembly/Assembly

Requisite Service

. Starter motor removal/installation (page 1 7-5)

Procedure

Q'ty

Remarks

Disassembly Order

Assembly is in the reverse order of disassembly.

(1)

Bolt

2

(2)

Rear cover

1

Install the rear cover with the tab of the blush holder plate

between the tabs on the inside of the rear cover,

(3)

O-ring

1

Record and store the shims in the same order they were

(4)

Shim

removed so they can be reinstalled in the original positions.

15)

Front cover

1

(6)

0-ring

1

(7)

Lock washer

1

(8)

Dust seal

1

(9)

Insulated washer

1

(10)

Shim

(ID

Armature

1

(12)

Terminal nut

1

(131

Washer

1

(14)

Insulated washer (large)

1

(15)

Insulated washer (small)

Blush holder assembly

1

Install the brush holder assembly with its tab aligning with

the groove in the motor case.

(18)

-terminal bolt supporter

1

Install the suppoter with its tab facing the brush holder side.

(19)

-terminal bolt

1

(20)

-motor brush

1

(21)

-brush spring

4

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