STARTER RELAY SWITCH
Starter motor will not turn
* Check for a blown fuse (15 A).
* Check that the battery is fully charged and in good condition.
* Check for loose or poorly connected battery cable and open circuit in battery cable.
* Check for loose or poorly connected starter relay switch terminals and connectors.
* Check for loose or poorly connected starter t motor cable. and oDen circuit in starter motor cable.
* With the ignition switch ON, push the starter switch and check for a "Click" sound from the starter relay switch.
* Check the starter relay coil ground line.
* Check the starter relay voltage.
* Check the starter relay switch operation.
Starter motor turns slowly
* Weak battery Poorly connected battery cable
* Poorly connected starter motor cable
* Faulty starter motor
Starter motor turns, but engine does not turn Faulty starter clutch
* Faulty starter clutch
Starter relay switch "clicks", but engine does not turn over
* Crankshaft does not turn due to engine problem
* Faulty starter reduction gear
* Faulty starter idle gear
STARTER MOTOR REMOVAL
Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. Remove the rubber cap, terminal nut and starter motor cable. Remove the two mounting bolts, cable guide and the starter motor from the crankcase and left crankcase cover. Remove the O-ring from the starter motor.
Remove the starter motor case bolts. Remove the front cover, thrust washer and seal ring. Remove the rear cover, shims and seal ring. Remove the armature from the motor case. Check the bearing and oil seal in the front cover for wear or damage. Check the commutator bars of the armature for discoloration.
NOTE: Do not use emery or sand paper on the commutator. Check for continuity between pairs of commutator bars. There should be continuity.
Check for continuity between each commutator ba and the armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and motor case. There should be no continuity.
Remove the following:
- insulator washers
- brush holder assembly
Remove the brushes from the brush holder and measure the brush length. Install the brushes into the brush holder. Install the brush holder assembly into the rear cover by aligning the tab of the holder with the groove in the rear cover.
Install the following:
- new O-ring
- insulator washers
Install the armature into the motor case while holding the armature tightly to keep the magnet of the case from pulling the armature against it.
CAUTION: The coil may be damaged if the magnet pulls the armature asainst the case.
Install the same number of shims in the same locations as noted during disassembly. Install a new seal ring. Install the rear cover by aligning the brush holder tab with the motor case groove.
Install the thrust washer and a new seal ring. Apply grease to the oil seal lip in the front cover. Install the front cover. Align the index lines on the front cover and motor case. Install the set plates and new O-rings onto the motor case bolts. Install and tighten the motor case bolts.
Coat a new O-ring with oil and install it into the starter motor groove. Install the starter motor into the left crankcase cover and onto the crankcase. Install the cable guide and mounting bolts, and tighten the bolts securely. Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut securely. Install the rubber cap over the motor terminal securely.
STARTER RELAY SWITCH INSPECTION
Shift the transmission into neutral. Turn the ignition switch ON. Push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the switch "CLICK". inspect the
relay switch using the procedure below. Remove the seathear fender.
Disconnect the yellowlgreen wire connector of the starter relay switch. Check for continuity between the wire harness side connector terminal and ground. If there is continuity when the transmission is in neutral or when the clutch is disengaged, the ground circuit is normal. (In neutral, there is a slight resistance due to the diode.)
STARTER RELAY VOLTAGE
Disconnect the yellowlred wire connector of the starter relay switch. Measure the voltage between the wire harness side connector terminal (+) and ground (-). If the battery voltage appears only when the starter switch is pushed with the ignition switch ON, the circuit is normal.
Disconnect the starter relay switch connectors and cables. Connect the fully charged 12 V battery positive terminal to the relay switch yellow/red wire connector terminal and negative terminal to the yellowlgreen wire connector terminal. There should be continuity between the large terminals while the battery is connected, and no continuity when the battery is disconnected.
CLUTCH DIODE INSPECTION
Remove the seathear fender Disconnect the starter relay switch (Yellow/green) and neutral switch (Light green) connectors. Check for continuity between the wire harness side connector terminals.
If there is continuity in one direction, the diode is normal. When there is continuity, a small resistance value will register.