Starting circuit cut-off system operation (xp500)

 

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 the following conditions are met:

Ч A brake lever is pulled to the handlebar (the brake light switch is closed) and the side-

 

stand is up (the sidestand switch is closed).

 

Ш Battery

 

Ш Main fuse

 

Ш Main switch

 

Ш Ignition fuse

 

Ш Engine stop switch

 

Ш Starting circuit cut-off relay 1

 

Ш Sidestand switch

 

Ш Signaling system fuse

 

Ш Front brake light switch

 

0 Rear brake light switch A Start switch

 

B Starter relay C Starter motor

 

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ELECTRIC STARTING SYSTEM ^{ELEC – +}

 

		D
		M
		C
		A
		B

EAS00756

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION (XP500A)

 

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 the following conditions are met:

GG A brake lever is pulled to the handlebar (the brake light switch is closed) and the side-

 

stand is up (the sidestand switch is closed).

 

Й Battery

 

Й Main fuse

 

Й Main switch

 

Й Signaling system fuse

 

Й Ignition fuse

 

Й Engine stop switch

 

Й Starting circuit cut-off relay 1

 

Й Front brake light switch

 

Й Rear brake light switch

 

0 Sidestand switch

 

К Starting circuit cut-off relay 2

 

К Start switch

 

К Starter relay

 

К Starter motor

 

 

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			ELEC
	ELECTRIC STARTING SYSTEM				–+
EAS00757	EAS00739

TROUBLESHOOTING

 

The starter motor fails to turn.

 

Check:

 

Л main, ignition and signaling system fuses

 

Л battery

 

Л starter motor

 

Л starting circuit cut-off relay 1

 

Л starting circuit cut-off relay 2 (XP500A)

 

Л starter relay

 

Л main switch

 

Л engine stop switch

 

Л sidestand switch

 

10.brake light switch (front and rear) 11.start switch

 

12.wiring connections

 

(of the entire starting system)

 

М Battery

 

Check the condition of the battery.

 

Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3.

Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F)

 

• Is the battery OK?

 

		YES		NO

• Clean the battery terminals.

 

• Recharge or replace the battery.

 

EAS00758

NOTE:

Н Before troubleshooting, remove the following part(s):

 

О front cowling

 

О leg shield

 

О footrest board

 

О fuel tank

 

П Troubleshoot with the following special tool(s).

 

Pocket tester 90890-03112, YU-03112-C

 

EAS00738

 

Р Main, ignition and signaling system fuses

 

Check the main, ignition and signaling sys-tem fuses for continuity.

 

Refer to “CHECKING THE FUSES” in chapter 3.

 

Are the main, ignition and signaling sys-tem fuses OK?

 

		YES		NO

Replace the fuse(s).

 

С Starter motor

 

Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.

 

 

WARNING

У A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, other-wise the jumper lead may burn.

У This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.

• Does the starter motor turn?

 

		YES		NO

Repair or replace the starter motor.

 

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ELECTRIC STARTING SYSTEM ^{ELEC – +}

EAS00759

 

Ф Starting circuit cut-off relay 1

 

Remove the starting circuit cut-off relay 1.

 

Connect the pocket tester (Ω Ч 1) and bat-tery (12 V) to the starting circuit cut-off relay 1 terminals as shown.

 

Positive battery terminal → red/black 1 Negative battery terminal → light green 2

 

XP500

 

Positive tester probe → green/yellow 3 Negative tester probe → green/yellow 4

 

XP500A

 

Positive tester probe → blue/white 3 Negative tester probe → white/red 4

XP500	XP500A

ХDoes the starting circuit cut-off relay 1 have continuity between green/yellow and green/yellow?

 

		YES		NO

Replace the starting circuit cut-off relay 1.

 

Ш Starting circuit cut-off relay 2 (XP500A)

 

Remove the starting circuit cut-off relay 2.

 

Connect the pocket tester (Ω Ч 1) and bat-tery (12 V) to the starting circuit cut-off relay 2 terminals as shown.

 

Check the starting circuit cut-off relay 2 for continuity.

 

Positive battery terminal →

 

green/yellow 1 Negative battery terminal → black 2

 

Positive tester probe → white/red 3 Negative tester probe → green/white 4

 

 

ЩDoes the starting circuit cut-off relay 2 have continuity between white/red and green/white?

 

		YES		NO

Replace the starting circuit cut-off relay 2.

 

 

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			ELEC
	ELECTRIC STARTING SYSTEM				–+
EAS00761	EAS00750

 

 

Ъ Starter relay

 

Remove the starter relay.

 

Connect the pocket tester (Ω Ч 1) and bat-tery (12 V) to the starter relay terminals as shown.

 

XP500

 

Positive battery terminal → black 1 Negative battery terminal →

 

blue/white 2

 

XP500A

 

Positive battery terminal → red/white 1 Negative battery terminal →

 

blue/white 2

 

Positive tester probe → red 3 Negative tester probe → black 4

 

 

Ы Does the starter relay have continuity between red and black?

 

		YES		NO

Replace the starter relay.

 

EAS00749

 

7. Main switch

Ь Engine stop switch

 

Check the engine stop switch for continu-ity.

Refer to “CHECKING THE SWITCHES”.

 

Is the engine stop switch OK?

 

		YES		NO

Replace the right handlebar switch.

 

EAS00752

 

Э Sidestand switch

 

Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

 

		YES		NO

Replace the side-stand switch.

 

EAS00751

 

10.Brake light switch (front and rear)

 

Ю Check the brake light switches for continu-ity.

Refer to “CHECKING THE SWITCHES”.

 

Ю Is each brake light switch OK?

 

		YES		NO

Replace the brake light switch(es).

 

Я Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”.

Я Is the main switch OK?

 

		YES		NO

Replace the main switch/immobilizer unit.

 

 

8 - 21

ELECTRIC STARTING SYSTEM ^{ELEC – +}

EAS00764

 

11.Start switch

 

А Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”.

А Is the start switch OK?

 

		YES		NO

Replace the right handlebar switch.

 

EAS00766

 

12.Wiring

 

ХCheck the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM (XP500)” or “CIRCUIT DIAGRAM (XP500A)”.

 

ХIs the starting system’s wiring properly connected and without defects?

 

YES

 

 

The starting system circuit is OK.

 

NO

 

 

Properly connect or repair the starting system’s wiring.

 

 

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_{STARTER MOTOR} ELEC ^{– +}

 

EAS00767

STARTER MOTOR

 

 

Order	Job/Part	Q’ty	Remarks
	Removing the starter motor		Remove the parts in the order listed.
	Fuel tank		Refer to “FUEL TANK” in chapter 3.
	Negative battery lead		Disconnect.
	Starter motor lead		Disconnect.
	Starter motor
			For installation, reverse the removal pro-
			cedure.

 

 

8 - 23

_{STARTER MOTOR} ELEC ^{– +}

 

 

Order	Job/Part	Q’ty	Remarks
	Disassembling the starter motor		Remove the parts in the order listed.
	Front bracket
	O-ring
	Shims
	Lock washer
	Oil seal
	Bearing
	Rear bracket
	Shims
	Brush holder set
	Armature assembly
A	Starter motor yoke
			For assembly reverse the disassembly
			procedure.

 

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_{STARTER MOTOR} ELEC ^{– +}

 

EAS00770

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