Checking the starter motor

 

Ц Check:

 

commutator

 

Dirt → Clean with 600 grit sandpaper.

 

Ч Measure:

 

commutator diameter a

 

Out of specification → Replace the starter motor.

Commutator wear limit 27 mm (1.06 in)

 

Ш 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 0.7 mm (0.03 in)

 

NOTE:

The mica of the commutator must be undercut to ensure proper operation of the commutator.

 

Ъ Measure:

 

armature assembly resistances (commuta-

 

tor and insulation)

 

Out of specification → Replace the starter motor.

 

▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼

 

Ы Measure the armature assembly resis-tances with the pocket tester.

 

 

8 - 25

_{STARTER MOTOR} ELEC ^{– +}

 

Pocket tester 90890-03112, YU-03112-C

Armature coil

 

Commutator resistance 1 0.0015 ~ 0.0025 Ω

 

at 20 °C (68 °F) Insulation resistance 2

 

Above 1 M Ω at 20 °C (68 °F)

 

b. If any resistance is out of specification, replace the starter motor.

 

▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲

 

 

Ь Measure:

 

brush length a

 

Out of specification → Replace the brushes as a set.

Brush length wear limit

Mm (0.16 in)

Э Measure:

 

brush spring force

 

Out of specification → Replace the brush springs as a set.

Brush spring force 7.65 ~ 10.01 N

(780 ~ 1,021 gf, 27.53 ~ 36.04 oz)

 

Ю Check:

 

gear teeth

 

Damage/wear → Replace the gear.

 

 

Ю Check:

 

bearing 1

 

oil seal 2

 

bushing 3

 

Damage/wear → Replace the defective part(s).

 

8 - 26

_{STARTER MOTOR} ELEC ^{– +}

 

EAS00772

ASSEMBLING THE STARTER MOTOR

А Install:

 

starter motor yoke 1

 

front bracket 2

 

rear bracket 3

 

NOTE:

Align the match marks a on the starter motor yoke with the match marks b on the front and rear bracket.

 

8 - 27

 

Rec B

 

DIAGRAMCIRCUIT

SYSTEMCHARGING

EAS00773

B/Y

B/L

B/Y B/L

Gy B

W

W

W

W

R

W

W

W

W

W

W

W

W

B

B

R

W W W

R

R

R

R

R

R

B/W B R/G

R/G BB

R

R

Y/L G/L R/W

R/W Lg Y/L

L/R

Br/R

ON

L/W

B

OFF

F

G (BLACK)

R/G R/W Y/L

R

R

P

G/L

B

B/W

Br/L

Br/L

L/W

H

L/W

B

Br/L

CHARGING

28-

L/R

B

B

J

B

B

I

(B

R/G

B

B

B

R/L

R L/G

SYSTEM

L/G R/G

L/G

R/G

R

A

L/G

Br/L

B

Br

C

R/Y

N

G/Y

R/W

ELEC

R/W

D

R/B

R

E

Br/R

Ch Br/W Dg

Dg Br/W Ch

O

P

Q

B

L/R

L/R

Br/L L/Y

2 A.C. magneto

(BLACK)

(BLACK)

R/G R/L

L/R Br/R R/Y Br/L

F

–

R R

L/R

R/W Br

R/W R/B G/Y

G/Y R/B R/W

B

B

Br L/W G/Y

L/W B Br

G Main fuse

+

™ B B

R/L R/G

(BROWN)

(BROWN)

Br/L R/Y Br/R L/R

L/W

ChDg

 

^attery tifier/regulator

_{CHARGING SYSTEM} ELEC ^{– +}

 

EAS00774 EAS00738

TROUBLESHOOTING

 

The battery is not being charged.

 

Check:

 

Б main fuse

 

Б battery

 

Б charging voltage

 

Б stator coil resistance

 

Б wiring connections

 

(of the entire charging system)

 

NOTE:

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

 

М rear cover

 

М battery cover

 

М left side cover moulding

 

М left side cover

 

Н Troubleshoot with the following special tool(s).

О Main fuse

 

Check the main fuse for continuity.

 

Refer to “CHECKING THE FUSES” in chapter 3.

 

Is the main fuse OK?

 

		YES		NO

Replace the fuse(s).

 

EAS00739

П 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?

 

	Pocket tester			YES		NO
	90890-03112, YU-03112-C

• Clean the battery terminals.

 

• Recharge or replace the battery.

 

 

8 - 29

_{CHARGING SYSTEM} ELEC ^{– +}

 

EAS00775 EAS00776

 

И Charging voltage

 

Connect the pocket tester (DC 20 V) to the battery as shown.

 

Positive tester probe →

 

positive battery terminal Negative tester probe →

 

Negative battery terminal

 

 

Й Start the engine and let it run at approxi-mately 5,000 r/min.

Й Measure the charging voltage.

 

Charging voltage 14.0 V at 5,000 r/min

 

NOTE:

 

Make sure the battery is fully charged.

 

Л Is the charging voltage within specifica-tion?

 

		NO			YES

The charging circuit is OK.

 

М Stator coil resistance

 

Remove the generator cover.

 

Connect the pocket tester (Ω Ч 1) to the stator coils as shown.

 

Positive tester probe → white 1 Negative tester probe → white 2

 

Positive tester probe → white 1 Negative tester probe → white 3

 

 

• Measure the stator coil resistances.

 

Stator coil resistance

0.22 ~ 0.26 Ω at 20 °C (68 °F) (between white and white)

 

• Is the stator coil OK?

 

		YES		NO

Replace the crank-shaft position sensor/ stator coil assembly.

 

EAS00779

 

Н Wiring

 

Check the wiring connections of the entire charging system.

 

Refer to “CIRCUIT DIAGRAM”.

 

Is the charging system’s wiring properly connected and without defects?

 

 

		YES		NO

 

Replace the rectifier/ regulator.

 

Properly connect or repair the charging system’s wiring.

 

8 - 30

 

 

8 - 31

 

 

L/W Y/L Y/G Gy/G W B/Y B/W Y/B L

R/W R/B O

A

Lg G/R Br/W P/W Y B/L L/Y Y/R W/Y R/L G/B B

B/Y

B/L

Br

Br

B/Y B/L

Gy B

U

Y/B

Y/B

R/B

W

W

GRIP WARMER

W

W

R

B/Y

O

O

WIRE HARNESS

V

SUB-WIRE HARNESS

W

W

W

B

G/R B/L

W W W

W W W

B

B/L

G/R

B

R

G/Y

R/L

(GREEN)

W

W W

R/B

R/B

B

Br/L

Br/L

G/R

R

R

Lg G/Y

B

Y/B

R

R

R

R/B G/Y

B/W B R/G

R/G BB

X

R

R

(BLUE)

K L

Y/L G/L R/W

R/W Lg

Y/L

L/R

Br/R

R/L

ON

L/W

B

B/L

Br/W

Br/W B/L

WIRE HARNESS

DC TERMINAL

R/L

SUB-WIRE HARNESS

R/G R/W Y/L

R

R

OFF

F

G (BLACK)

R/B

L/Y

(GREEN)

P

G/Y Lg

R/L L/Y

Br/W

C

G/LB B/W

Br/L

Br/L

L/W

H

L/Y

P/W

L/W

B

R/L

Gy/G

[

Y

Y

Br/L

B/L

B/L P/W

L

L/R

J

L/W

R/L

G

T

R/L O/B

R/B R/L

P/W

B

B

B

B

B

B

B

M

Y (BLACK)

L

(BLACK)

I

(BLACK)

(BLACK)

R/B

R/B

R/L

WIRE HARNESS

HEADLIGHT

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