Elec

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12. Start switch

CCheck the start switch for continuity.

Refer to "CHECKING THE SWITCHES". CDs the start switch OK?

Replace the right handlebar switch.

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13. Wiring

CCheck the entire starting system's wiring.

Refer to "CIRCUIT DIAGRAM". Os the starting system's wiring properly connected and without defects?

Properly connect or repair the starting system's wiring.

The starting system circuit is OK.

Order

Job/Part

Q'ty

Remarks

Removing the starter motor

Remove the parts in the order listed.

1

Starter motor lead

1

2

Starter motor assembly

1

For installation, reverse the removal

procedure.

1

Disassembling the starter motor

Disassembly the pats in the order listed.

Starter motor front cover

1

2

Washer set

1

(3

Starter motor rear cover

1

(3)

washer set

1

©

Brush holder/brush

1/1

® ®

Armature assembly

1

Starter motor yoke

1

For assembly, reverse the disassembly

procedure

Checking The Starter Motor

1. Check: Commutator

Dirt ^ Clean with 600 grit sandpaper.

2. Measure: CCommutator diameter @

Out of specification ^ Replace the starter motor.

Min. commutator diameter 27 mm

Out of specification ^ Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator.

Mica undercut 0.7 mm

The mica must be undercut to ensure proper operation of the commutator.

4. Measure: Carmature assembly resistances (commutator and insulation)

Out of specification ^ Replace the starter motor.

a. Measure the armature assembly resistances with the pocket tester.

Pocket tester 90890-03112

Armature assembly

Commutator resistance ® 0.025 - 0.035 W at 200C Insulation resistance (2) Above 1 MW at 20 oC

b. If any resistance is out of specification, replace the starter motor.

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5. Measure: Cbrush length (a) Out of specification as a set.

Replace the brushes

Min. brush length 5 mm

Min. brush length 5 mm

6. Measure: Cbrush spring force Out of specification springs as a set.

Replace the brush

Brush spring force

Brush spring force

7. Check: Cgear teeth

Damage/wear

8. Check: COil seal

Damage/wear part(-s).

Replace the gear.

Replace the defective

Assembling The Starter Motor

1. Install: Cbrush holder ®

Align the tab ® on the brush holder with the slot ® in the starter motor rear cover.

2. Install: Cstarter motor yoke ® CO-rings ® INSWM Cstarter motor front cover (3 Cstarter motor rear cover® Cbolts

NOTE:

Align the match marks @ on the starter motor yoke with the match marks ® on the front and rear covers.

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