ELECTRICAL SYSTEM 16-41

Electric Starter System

Starter Motor Removal

•Drain the coolant (see Coolant Change in the Periodic Maintenance chapter).

•Remove:

Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)

Starter Clutch Cover (see Starter Idle Gear Removal in the Crankshaft/Transmission chapter)

Clamp Screw [A] (Loosen) Water Hose [B]

•Slide out the rubber cap [A].

•Remove the starter motor cable terminal bolt [B].

•Remove the starter motor mounting bolts [C].

•Take out the starter motor [D] from the right side of the

motorcycle.

Starter Motor Installation

CAUTION

Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor.

•Clean the starter motor legs [A] and crankcase [B] where the starter motor is ground.

•Replace the O-ring [A] with a new one.

•Apply grease to the new O-ring.

•Tighten the starter motor mounting bolts temporarily.

•Install the starter clutch cover (see Starter Idle Gear Installation in the Crankshaft/Transmission chapter).

•Tighten:

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

16-42 ELECTRICAL SYSTEM

Electric Starter System

•Install the starter motor cable [A] as shown in the figure.

•Tighten:

Torque - Starter Motor Cable Terminal Bolt [B]: 2.9 N·m (0.30 kgf·m, 26 in·lb)

•Slide back the rubber cap to the original position.

Starter Motor Disassembly

•Take off the starter motor through bolts [A].

•Remove:

Left-hand End Cover [A] Right-hand End Cover [B] Armature [C]

Yoke [D]

Starter Motor Assembly

•Apply a thin coat of grease to the oil seal [A].

•Fit the groove [B] of the toothed washer [C] on the projection [D] left-hand end cover.

•Install the washer [E].

ELECTRICAL SYSTEM 16-43

Electric Starter System

•Press the springs holding the brush leads with suitable clips [A] as shown in the figure.

•Put the armature [B] among the brushes.

•Install the new O-rings [A] as shown in the figure.

•Align the groove [A] in the right-hand end cover and the hollow mark [B] on the yoke.

•Align the hollow mark [A] on the left-hand end cover and the hollow mark [B] on the yoke.

Brush Inspection

•Measure the length [A] of each brush.

If any is worn down to the service limit, replace the brush holder assembly.

Starter Motor Brush Length

Standard: 7 mm (0.28 in.)

Service Limit: 3.5 mm (0.14 in.)

16-44 ELECTRICAL SYSTEM

Electric Starter System

Commutator Cleaning and Inspection

•Smooth the commutator surface [A] if necessary with fine emery cloth [B], and clean out the grooves.

•Measure the diameter [A] of the commutator [B].

If the commutator diameter is less than the service limit, replace the starter motor with a new one .

Commutator Diameter

Standard: 24 mm (0.94 in.)

Service Limit: 23 mm (0.91 in.)

Armature Inspection

•Using the × 1 Ω hand tester range, measure the resistance between any two commutator segments [A].

Special Tool - Hand Tester: 57001-1394

If there is a high resistance or no reading (∞) between any two segments, a winding is open and the starter motor must be replaced.

•Using the highest hand tester range, measure the resistance between the segments and the shaft [B].

If there is any reading at all, the armature has a short and the starter motor must be replaced.

NOTE

○Even if the foregoing checks show the armature to be good, it may be defective in some manner not readily detectable with the hand tester. If all other starter motor and starter motor circuit components check good, but the starter motor still does not turn over or only turns over weakly, replace the starter motor with a new one.

Brush Lead Inspection

•Using the × 1 Ω hand tester range, measure the resistance as shown in the figure.

Terminal Bolt and Positive Brush [A] Right-hand End Cover and Negative Brush [B]

Special Tool - Hand Tester: 57001-1394

If there is not close to zero ohms, the brush lead has an open. Replace the right-hand end cover assembly.