ELECTRIC STARTER SYSTEM SYSTEM DIAGRAM (1) IGNITION 2) STARTER SWITCH (4) STARTER ELEY (8) BATTERY SwircH (5) STARTER MOTOR ~ LGR weremral LIGHT FUSE BA Riel NEUTRAL cuuTCH swITcH SWITCH BATTERY 12vaAH MAIN FUSE IGNITION 208 switcH i——o ee Yee YELLOW GRANGE Buss BME Le Ucar Lue Gon REN UT een en on. Woe WE GA 18-018. ELECTRIC STARTER SYSTEM SYSTEM DIAGRAM 18-0 STARTER MOTOR 18.3 » SERVICE INFORMATION 18.1 STARTER RELAY SWITCH 18.7 i TROUBLESHOOTING 18-2 CLUTCHDIODE 18.8 SERVICE INFORMATION GENERAL © ‘The starter motor can be removed with the engine in the frame. SPECIFICATIONS: » smu tint ITEM STANDARD SERVICE LIMIT Stortor motor brush length 12.0-13.0 (0.470.651) 6.5 (0.26) » » » 18-1ELECTRIC STARTER SYSTEM TROUBLESHOOTING NOTE + The starter motor could turn when the transmission is in neutrel or the clutch disengaged. + Check the following items before troubleshooting the system. ‘Main (20A) and cub (110A and 18A) fuses for burn. — Battery and starter motor cables for loose connection. — Battery discharged. Starter motor deo not turn 1-1. Check the starter ‘elay switch for opera. "cucK” ton. You should hear the relay ‘CLICK” HEARD 1.2. Apply battery voltage to the starter motor when the starter switch buttorn is de> [SSC diractty anc check the operation, pressed. (page 18-7) Of OO TURN DO NOT TURN ‘CLICK’ NOT HEARD + Loose Or poorly con + Faulty starter motor tact cables (page 18-3) + Faulty starter relay ‘witch (page 13-7) ABNORMAL 2. Ghack the neutral indicator ter function, ABNORMAL airy neutral switch ipage 19-3) + Locse or poorly contact connector of the neu- tral switch NORMAL Faulty ignition owiteh (oege 19-6) ck the starter ely switch vottege [ 8 check ae starter rey eween vata NO VOLTAGE Loca0 oF poorly contact connacror of the Hage ‘clutch diode + Faulty starter switch (page 19-8) parreny + Faulty clutch diode (oage 18-8} VOLTAGE COMES + Open or shert circuit in wire hamess % Check the starter relay switch for eontinus |__ABNORMAL | stern ty (page 1-7 ERO es Fauity starter relay switch NORMAL NORMAL. Louse or poor contaet at starter relay svriteh Starter motor tums engira slowly + Low specific gravity Excessive resistance in circuit (Section 9) + Binding in starter motor shait [Section 9) Starter motor turns, but engine does not turn Foulty starter clutch (Section 9} Foully starter motor geers (Section 9} Feulty starter mozor er kdle gear (Section 9) Starter motor and engine turns, but engine does not start Faulty ignition system Engine problems (Section 20) = Low compression — Fouled spark plug 18-2ELECTRIC STARTER SYSTEM STARTER MOTOR REMOVAL = + With the Ignition switch OFF, remove the negat battery bajore rervicing the starter motor. ‘cable at the Romove the clutch eabla holder from the starter motor. Disconnect the starter motor cable. Romove the motor mounting bolts, starter motor, set rubber and moter stay DISASSEMBLY Femove the following components = motor case alts = front caver and rear cover = armature Note Record the lee: jon and number of shims (2) REAR (3) BOLTS. COVER INSPECTION Check for continuity trom the cable terminal 10 each brush. CONTINUITY: RORMALELECTRIC STARTER SYSTEM Chack for continuity from the eable terminal to the front cover. NNO CONTINUITY: NORMAL Meesure exch brush length. SERVICE LIMIT: 8.5 mm (0.2 ink Inspect the commutator bars for disealoretion, ‘The bars discolorad in pairs indicate grounded armature coils Chock for continuity between pars of commutator bars % Thora should be continuity. 18-4ELECTRIC STARTER SYSTEM. Check for continuity between inalvicual commutator bars and the armature sheft. » Check the dust seal of the front cover for weer ar fatigue. 11) DUST SEAL (2) FRONT COVER ASSEMBLY 11) CASE 121 srainas (3) ARMATURE % SHIMS (a) SPRINGS (2) TERMINAL, > Pag ne Rabe (5) REAR COVER rine ith ) siwacnt WASHERS 18-5ELECTRIC STARTER SYSTEM Install the brush holder onte thereat cover, aligning the tang of ‘the holder with the slot of tho tear cover. Install the armature into the motor case. Install the shims in the same location and number when disas sombled, Install the O-rings on the motor case. Install the rer cover, algning Is slot vith the tang ot the brush holder. Install the shims in the same location and number when disas- sombled. Install she lock washer, aligning Its tabs with the slots of the: front cover. Apnly grease to the dust seal Install the Fost cover. Align the index marke of the front cover, 2028 and rear cover #8 shown, Tighten the motor case bolts securely with the O-rngs and washers, Apply eil to tho O-ring and installt into the frant ecee granve. 11) BRUSH HOLDER (3) REAR COvER i a. (1) ARMATURE f (2) -nINGS (a) sins (3) ALIGN « vocs, WASHER (2) oust SEAL = Sica 4) SHIMS |3! FRONT COVER (1) INDEX MARKS: (3) O-FINGS (2) BOLTS AND WASHERS 18-6ELECTRIC STARTER SYSTEM INSTALLATION Set the motor stay and set rubber ento the engine. Install the starter matar on the rubber and stay, and tighten the mounting bolts. NOTE, Install the groune cable with ene mounting bolt as shawn. Connect the moter cable to the motor terminal Put the rubser cap en the terminal Connect the battery negative cable. a grooms Cae Install che clutch cable holder, aligning ite holo with the bose (1) CABLE HOLDER: on the starer motor, and secure with the bolt, ihe &- STARTER RELAY SWITCH OPERATION INSPECTION Remove the rear fender (page 15-8) Depress the starter switch button with the ignition ON. The cal is normal if the starter rolay switeh clicks. VOLTAGE INSPECTION If tho ewiteh ‘CLICK’ is not haaro, measure the veltaga be tween the yellowired [+] and green‘ted -} wires of the relay connector. The battery voltage should appear when the starter switch button is depressed with the igntion switch ON nd neutral position Porform the lollowing inspeotion if the battery voltage appeared between the yellonired and greenited wires Oy stawien ml 18-7ELECTRIC STARTER SYSTEM CONTINUITY INSPECTION Famave the starter relay switch. Connect an ohmmeter 10 the starter relay switch largo termi pals. Connect a fully charged 12 ¥ battery positive wire to the start fr relay switch Yellow/Red wire terminal and battery negative wire ta the Green/Red wire terminal. Check for continuity between the starter relay ewiteh termi nals, ‘There should be continuity while the 12'V battery is connected to the starter relay switch terminals end should be no continui- ty when the battory i¢ disconnastod. CLUTCH DIODE NoTE + Clutch disde is lovated under tha seat INSPECTION ‘Check for consinuity with an ohmreneter NORMAL DIRECTION: CONTINUITY REVERSE DIRECTION: NO CONTINUITY 18-8 ‘88 SHOWN: