Electric Starter

SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING

18-1

18-2

18-0

STARTER MOTOR STARTER RELAY SWITCH DIODE

18-11

18-10

18-4

SERVICE INFORMATION

GENERAL

• Always turn the ignition switch to "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury.

• When checking the starter system, always follow the steps in the troubleshooting flow chart (page 18-2).

• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.

• If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.

• See section 10 tor starter clutch servicing.

• See section 19 for following components:

- Ignition switch

- Engine stop switch

- Starter switch

- Neutral switch

- Side stand switch

- Clutch switch

SPECIFICATION

ITEM

STANDARD

SERVICE LIMIT

Starter motor brush length

TORQUE VALUE

Starter motor terminal nut

TROUBLESHOOTING

Starter motor does not turn

• Check tor blown main or sub fuses before servicing.

• Make sure the battery is fully charged and in good condition.

Check the starter relay switch operation. You should hear the relay click when the starter switch button is depressed.

Click heard

Apply battery voltage to the starter motor directly and check the operation.

Normal

Abnormal

Click not heard

Poorly connectcd starter motor cable. Faulty starter relay switch (page 18-10).

Faulty starter motor (page 18-4).

Disconnect the starter relay switch connector, and check the relay coil ground wire lines for continuity as stated below:

1. Green/Red terminal-clutch switch diode ncu tral switch line (with the transmission in neutral and clutch lever released).

2. Green/Red terminal/clutch switch side stand switch line (in any year except neutral, and with the clutch lever pulled in and the side stand up).

Abnormal

Faulty neutral switch (page 19-20)

Faulty neutral diode

Faulty clutch switch

Faulty clutch/side stand diode

Faulty side stand switch

Loose or poor contact connector

Open circuit in wire harness

Normal

Connect the starter relay switch connector. With the ignition switch turned to "ON" and the starter switch pushed, measure the starter relay voltage at the starter switch connector (between Yellow/Red (+) and ground (-).

No voltage

Faulty ignition switch. Faulty starter switch. Blown out main or sub-fuse. Loose or poor contact of connector. Open circuit in wire harness.

Battery voltage registered

Check the starter relay switch operation.

Normal

Loose or poor contact starter relay switch connector.

Abnormal

Faulty starter relay switch.

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

Check the clutch switch operation.

Normal

Check the side stand switch.

Normal

Faulty clutch switch.

Normal

• Faulty clutch switch.

Normal

—-------- ------*** • Open circuit in wire harness.

• Loose or poor contact connector.

Starter motor turns engine slowly

• Low battery voltage

• Poorly connected battery terminal cable

• Poorly connected starter motor cable

• Faulty starter motor

• Poor 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 drive geai

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

• Crankshaft does not turn due to engine problems

STARTER MOTOR

REMOVAL

Support the front end of fuel tank (page 3-4). Drain the coolant (page 6-4). Remove the throttle body (page 5-60). Remove the thermostat housing (page 6-7).

With the ignition switch turned to "OFF", remove the negative cable at the ballery before servicing the starter motor.

Be careful not to Remove the nut and the starter motor cable from the damage the water starter motor. nose.

Remove the starter motor mounting bolts and ground cable.

Pull the starter motor out of the crankcase.

DISASSEMBLY

Remove the following: Starter motor case bolts/O-rings

CASE BOLTS

Record we location and number of shims.

- Front cover

- Seal ring

- Lock washer

- Insulated washer

SEAL HING

SEAL HING

INSULATED WASHER

SHIM(S)

FRONT COVER

INSULATED WASHER

FRONT COVER

LOCK WASHER

SHIM(S)

LOCK WASHER

Remove the following:

- Rear cover assembly

- Seal ring

- Shims Armature

INSPECTION

Cheek the bushing in the rear cover for wear or damage.

BUSHING

Check the oil seal and needle bearing in the front cover for deterioration, wear or damage.

Do not use emery Check the commutator bars of the armature for dis-

dolh or sand coloration. paper on the commutator.

SEAL RING

REAR COVER

ARMATURE

SHIM

OIL SEAI. NEEDLE BEARING

OIL SEAI. NEEDLE BEARING

COMMUTATOR

ARMATURE

COMMUTATOR

BARS

Brush Holder Oring Wire

Check for continuity between the pairs of commutator bars.

There should be continuity.

BRUSH

Check for continuity between each commutator bar and the armature shaft. There should be no continuity.

Check tor continuity between the insulated brush and cable terminal (the indigo colored wire or the insulated brush holder). There should be continuity.

BRUSH

Check for continuity between the cable terminal and the rear cover.

There should be no continuity.

Remove the following: BRUSH HOLDER

- Insulators VjBfjV O-ring

- Brush holder assembly INSULATORS J

- BrushAerminal

WASHER

O-RING

Inspect the brushes for damage and measure the brush length.

ASSEMBLY

REAR COVER

BRUSH

BRUSH HOLDER

INSULATORS

SHIMS

WASHER

ARMATURE

MOTOR CASE

SEAL RING

SHIM

INSULATED WASHER

LOCK WASHER

FRONT COVER

Install the brushes into the brush holder.

Install the cable terminal and brush holder into the rear cover, aligning the holder tab with the rear cover groove.

Install the following:

- Insulated washers

- Washer

Install the armature in the motor case. When installing the armature into the motor case, hold the armature tightly to prevent the magnet from pulling the armature against the ease.

NOTICE

The coil may be damaged if the magnet pulls the armature against the case.

ARMATURE MOTOR CASE

Install the same number of shims in the same location as noted during disassembly.

Install a new seal ring onto the motor ease.

Apply a thin coat of grease to the armature shaft end.

Install the rear covcr, while pushing in the brushes into the brush holder and aligning the brush holder tab with the motor case groove.

Install the shims Install the shims and insulated washer onto the arma-properly as noted ture shaft. during removal. |nsta|| a new seal ring onto the motor case.

Apply grease to the oil seal lip and needle bearing in the front cover.

Install the lock washer onto the front cover. Install the front covcr.

ALIGN

SEAL RING FRONT COVER

\ INSULATED WASHER

LOCK WASHER

Install new O-rings onto the motor case bolts. Install and tighten the case bolts securely.

BOLTS

INSTALLATION

Coat a new O-riny with oil and install it into the starter motor groove.

0 RING

Install the starter motor into the crankcase.

Route the starter motor cable and ground coble. Be careful not to Install the ground coble and mounting bolts, and damage The waier tighten the bolts securely.

hose, install the starter motor cable, then tighten the termi nal nut to the specified torque.

Install the rubber cap securely.

Install a new O-ring into the thermostat housing groove.

Install the thermostat housing to the cylinder head

Damaged Motor Electric Bike

O-RINGS

BOLTS

MOTOR

O-RINGS

MOTOR

STARTER MOTOR CABLE ¡¡2 STARTER MOTOR

BOLTS

GROUND CABLE

Install and tighten the mounting bolts. Install the following:

- Thermostat housing/thermostat (page 6-6).

Fill the system with the recommended coolant (page 6 4).

STARTER RELAY SWITCH

Relay Switch For Honda Cbr

STARTER RELAY SWITCH

OPERATION INSPECTION

Shift the transmission into neutral. Turn the ignition switch to "ON" and engine stop switch on.

Push the starter switch button.

The coil is normal if the starter relay switch clicks.

If you do not hear the switch click, inspect the relay switch using the piocedure below.

STARTER RELAY SWITCH

GROUND LINE INSPECTION

Disconnect the starter relay switch 4P connector.

Check for continuity between the Green/Red wire (ground line) and ground.

If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is retracted, the ground circuit is normal (in neutral, there is a slight resistance due to the diode).

STARTER RELAY VOLTAGE INSPECTION

Connect the starter relay switch 4P connector.

Shift the transmission into neutral. Measure the voltage between the Yellow/Red wire terminal (+) and ground (-).

If the battery voltage appears only when the starter switch is pushed with the ignition switch turned to "ON" and the engine stop switch on, it is normal.

Cbr 600 Ignition WiringTake Starter F4i

BOLTS

ECT SENSOR CONNECTOR

THERMOSTAT HOUSING k tmrnm^Êm niwrwi uimmm ad

1990 Honda Cbr 600 Fuse Box
RELAY SWITCH CONNECTOR

CONTINUITY INSPECTION

Disconnect the starter relay connector and cables.

Connect an ohmmeter to the large starter relay switch terminals.

Connect a fully charged 12-V battery to the starter relay switch connector terminals (Yellow/Red and Green/Red).

Check for continuity between the starter relay switch terminals.

There should be continuity while 12-V battery is connected to the starter relay switch connector terminals and should be no continuity when the battery is disconnected.

DIODE

REMOVAL

Remove the seat (page 2-2). Open the fuse box and remove the diode.

Honda Cbr 600 Diode Pink Cable Location

INSPECTION

Check for continuity between the diode terminals. When there is continuity, a small resistance value will register.

If there is continuity, in one direction, the diode is normal.

INSTALLATION

Install the diode in the reverse order of removal.

DIODE

Speed Sensor Location Cbr 600rr

STARTER RELAY SWITCH

SYSTEM LOCATION

FRONT BRAKE LIGHT SWITCH

IGNITION SWITCH

LEF1 HANDLEBAR SWITCH

TURN SIGNAL REl AY

lirADLIGHT RELAY

HORN

FRONT BRAKE LIGHT SWITCH

IGNITION SWITCH

RIGHT HANDLEBAR SWITCH

OIL PRESSURE SWITCH

EOT,THERMO SENSOR

REAR BRAKE LIGHT SWITCH

HORN

Pedestal Fan Wiring Diagram

RADIATOR FAN MOTOR SWITCH

CLUTCH V (T^-S WITCH

RIGHT HANDLEBAR SWITCH

OIL PRESSURE SWITCH

EOT,THERMO SENSOR

REAR BRAKE LIGHT SWITCH

RADIATOR FAN MOTOR SWITCH

NEUTRAL SWITCH

Yamaha 600 Motorcycle Cable Diagrams

SPEED SENSOR

SIDE STAND SWITCH

NEUTRAL SWITCH

SPEED SENSOR

SIDE STAND SWITCH

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Responses

  • fosca
    How to bypass the starter relay on a honda cbr600 f4i?
    5 years ago

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