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ELECTRIC STARTING SYSTEM
ELEC +i
EAS00755
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
Main fuse
Battery
Starter relay
Starter motor
Start switch
Engine stop switch
Main switch
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ELECTRIC STARTING SYSTEM
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STARTING CIRCUIT CUT-OFF SYSTEM OP-
ERATION
If the engine stop switch is set to “ # ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met:
8 The brake lever(front or rear) is pulled to the handlebar(the brake light switch is closed) and the sidestand(optional) is up(the sidestand switch(optional) is closed).
1 Battery
2 Main fuse
3 Main switch
4 Front brake light switch
5 Rear brake light switch
6 Engine stop switch
7 Starting circuit cut-off relay
8 Sidestand switch(optional)
9 Start switch
0 Starter relay q Starter motor
8-15
EAS00757
TROUBLESHOOTING
The starter motor fails to turn.
Check:
1 . main fuse
2. battery
3. starter motor
4. starting circuit cut-off relay
5. starter relay
6. main switch
7. brake light switch(front and rear)
8. engine stop switch
9. sidestand switch(optional)
10.start switch
11.wiring connections
(of the entire starting system)
ELECTRIC STARTING SYSTEM
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1. Main Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSE” in chapter 3.
* Is the fuse OK?
V
YES
4
NO
Replace the fuse.
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2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3. NOTE:
8 Before troubleshooting, remove the following part(s):
1 . battery cover/front cover
2. side cover(left and right)
3. front fork upper cover
4. front fork cover(left and right)
5. leg shield1
6. air filter assembly
8 Troubleshoot with the following special tool(s).
Pocket tester
90890-03112 (YU-03112-C)
II Minimum open-circuit voltage
12.8 V or more at 20°C (68°F)
• Is the battery OK?
V
YES
4
NO
• Clean the battery terminals.
• Recharge or replace the battery.
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ELECTRIC STARTING SYSTEM
ELEC +1 I
EAS00759
4. Starting circuit cut-off relay
• Remove the starting circuit cut-off relay.
• Connect the pocket tester ( Q x 1) and battery (12 V) to the starting circuit cut-off relay coupler as shown.
Positive battery terminal -» red/white ®
Negative battery terminal -> light green
Positive tester probe -» green/yellow ®
Negative tester probe -> green/yellow ®
1 3 w
8 A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.
8 This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.
• Does the starter motor turn?
0 YES NO I
Repair or replace the starter motor.
2 4
• Does the starting circuit cut-off relay have continuity between green/yellow and green/ yellow?
&
YES NO l
Replace the starting circuit cut-off relay
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ELECTRIC STARTING SYSTEM
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5. Starter relay
• Remove the starter relay .
• Connect the pocket tester ( Q x 1) and battery (12 V) to the starter relay coupler as shown.
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7. Brake light switch(front and rear)
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is each brake light switch OK?
Positive battery terminal ^green/yellow ©
Negative battery terminal -» blue/white (2)
Positive tester probe -» red (3)
Negative tester probe -» red (4)
V
YES NO I
Replace the brake light switch(es).
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8. Engine stop switch
• Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the engine stop switch OK?
V
YES NO
*
Replace the right handlebar switch.
V
YES NO 4
Replace the starter relay.
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6. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
V
YES
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9. Sidestand switch(optional)
• Check the sidestand switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the sidestand switch OK?
V
YES
NO 4
Replace the main switch.
I NO
Replace the sidestand switch.
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10. Start switch
• Check the start switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the start switch OK?
V
YES NO
Replace the right handlebar switch.
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ELECTRIC STARTING SYSTEM
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11. Wiring
• Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the starting system’s wiring properly connected and without defects?
YES
V
The starting system circuit is OK.
*
NO
Properly connect or repair the starting system’s wiring.
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EAS00767
STARTER MOTOR
ELECTRIC STARTING SYSTEM
ELEC +i
® MM
®
Order Job/Part
Removing the starter motor
Front cover
Single seat/Trunk
Air filter assembly
1
2
Starter motor lead coupler
Starter motor
5
6
7
8
1
2
3
4
Disassembling the starter motor
O-ring
Gasket
Stator assembly
O-ring
Armature coil
Brush
Plate washer
Bracket
8-20
Q’ty
1
1
Remarks
Remove the parts in the order listed.
Refer to “COVER AND PANEL”in chapter 3.
Refer to“ENGINE REMOVAL”in chapter
5.
Disconnect.
For installation, reverse the removal procedure.
Disassemble the parts in the order listed.
1
1
1
1
1
2
1
1
Refer to“ASSEMBLING THE STARTER
MOTOR”.
For assembly, reverse the disassembly procedure.
ELECTRIC STARTING SYSTEM
ELEC + 1
EAS00769
CHECKING THE STARTER MOTOR
1. Check:
• commutator
Dirt -» Clean with 600-grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification -» Replace the starter motor.
Commutator wear limit
16.6 mm (0.65 in)
3. Measure:
• mica undercut a
Out of specification -» Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Mica undercut
1.35 mm (0.05 in)
NOTE:
The mica of the commutator must be undercut to ensure proper operation of the commutator.
8-21
4. Measure:
• armature assembly resistances (commutator and insulation)
Out of specification -» Replace the starter motor.
T T T T T T T T T T T T T T T T T T T T T T T a. Measure the armature assembly resistances with the pocket tester.
Pocket tester
90890-03112 (YU-03112-C) a
Armature coil
Commutator resistance 1
0.0378 ~ 0.0462 at 20°C (68°F)
Insulation resistance 2
Above 1 M at 20°C(68°F)
ELECTRIC STARTING SYSTEM
ELEC +i b. If any resistance is out of specification, replace the starter motor.
• • • • • • • • • • • • • • • • • • • • • • •
5. Measure:
• brush length a
Out of specification -» Replace the brushes as a set.
Brush length wear limit
3.5 mm (0.14 in)
6. Measure:
• brush spring force
Out of specification -» Replace the brush springs as a set.
Brush spring force
3.92 ~ 5.88N(400 ~ 600gf, 14.11 ~
21.16oz)
7. Check:
• gear teeth
Damage/wear -» Replace the gear.
8. Check:
• bearing ©
• oil seal ©
• bush (3)
Damage/wear -» Replace.
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ASSEMBLING THE STARTER MOTOR
1. Install:
8brush seat 1
2. Install:
8 w a s h e r 1
8armature coil 2
8o-ing New 3
8stator assembly 4
3 . Install:
• bracket
• bolts (T)
X I 5 Nm (0.5 m * kg, 3.6 ft * lb)
NOTE:
Align the match marks a on the starter motor yoke with the match marks b on the bracket.
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