16-46 ELECTRICAL SYSTEM

Electric Starter System

Starter Motor Removal
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

• Remove:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
Air Cleaner Housing (see Air Cleaner Housing Removal
in the Fuel System (DFI) chapter)
• Slide out the rubber cap [A].
• Remove the starter motor cable terminal nut [B].
• Remove the mounting bolts [C].
• Pull out the starter motor [D].
Starter Motor Installation
CAUTION
Do not tap the starter motor shaft or body. Tapping
the shaft or body could damage the motor.

• When installing the starter motor, clean the starter mo-

tor legs [A] and crankcase [B] where the starter motor is
grounded.

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

• Apply a non-permanent
Apply grease to the O-ring.
• the bolts and tighten the locking
bolts.
agent to the threads of

Torque - Starter Motor Mounting Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

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

About 20° [B]
Front [C]
• Tighten:
Torque - Starter Motor Cable Terminal Nut: 6.0 N·m (0.61
kgf·m, 53 in·lb)
• Slide back the rubber cap to the original position.
 ELECTRICAL SYSTEM 16-47
Electric Starter System
Starter Motor Disassembly
• Remove the starter motor (see Starter Motor Removal).
• the both end starter
Take off the motor through bolts [A] and remove
covers [B].

• Pull out the armature [A] out of the yoke [B].

NOTE
○Do not remove the circlip [C] from the shaft.

• Remove the starter motor terminal locknut [A].

• Pull out the brushes from the brush holder [A].

• Brush Springs [B]
Remove:

Starter Motor Terminal [C]

Positive Brush Assembly [D]
Screw [E]
Negative Brush Assembly [F]
Brush Holder

Starter Motor Assembly

• Be sure that the stopper [A] is in position.
• Align the hole [B] of the brush holder [C] to the boss [D]
of the right-hand end cover [E].
16-48 ELECTRICAL SYSTEM
Electric Starter System

• Align the stoppers [A] of the negative brush assembly [B]

to the grooves [C] of the brush holder [D].
• Tighten the screw securely.

• Align the stoppers [A] of the positive brush assembly [B]

to the grooves [C] of the brush holder [D].
• Install the starter motor terminal.

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

• New O-ring
Install the following parts to the starter motor terminal [B].

Collar [C]
Washer [D]
Starter Motor Terminal Locknut [E]
○Install the collar so that stepped side faces outward.
•Tighten:
Torque - Starter Motor Terminal Locknut: 11 N·m (1.1
kgf·m, 97 in·lb)

• Install the brush springs [A] and insert the brushes [B].

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

 ELECTRICAL SYSTEM 16-49
Electric Starter System

• Replace the O-rings [A] with new ones.

• hollow sidearmature
Insert the [B] so that commutator side [C] faces
[D] of the yoke [E].

• Align the marks [A] to assembly the yoke and the end
covers [B].

• Replace the O-rings [A] with new ones.

• Tighten the through bolts [B].
Torque - Starter Motor Through Bolts: 5.0 N·m (0.51 kgf·m,
44 in·lb)

Brush Inspection
• Measure the length of each brush [A].
If any is worn down to the service limit, replace the brush
assembly.
Starter Motor Brush Length
Standard: 12 mm (0.47 in.)
Service Limit: 6.5 mm (0.26 in.)

Commutator Cleaning and Inspection

• Clean the metallic debris off the between commutator
segments [A].
NOTE
○Do not use emery or sand paper on the commutator.
• Check the commutator for damage or abnormal wear.
Replace the starter motor with a new one if there is any
damage or wear.
• Visually inspect the commutator segments for discol-
oration.
Replace the starter motor with a new one if discoloration
is noticed.
16-50 ELECTRICAL SYSTEM
Electric Starter System
Armature Inspection
• Using the × 1 Ω hand tester range, measure the resis-
tance 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 resis-
tance 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 resis-
tance as shown.
Terminal Bolt and Positive Brushes [A]
Right-hand End Cover and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is not close to zero ohms, the brush lead has an
open. Replace the brush assembly.

Right-hand End Cover Inspection

• Using the highest tester range, measure the resistance
as shown.
Terminal Bolt and Right-hand End Cover [A]
Terminal Bolt and Negative Brushes [B]
Special Tool - Hand Tester: 57001-1394
If there is any reading, the brush assy and/or terminal bolt
assy have a short. Replace the starter motor.

Starter Relay Inspection

• Remove:
Bolt [A]
Cover [B]
 ELECTRICAL SYSTEM 16-51
Electric Starter System

• Disconnect:
Connector [A]
Starter Motor Cable [B]
Battery Positive (+) Cable [C]
• Remove the starter relay.
CAUTION
The battery positive (+) cable with the rubber cap is
connected directly to the battery positive (+) termi-
nal even when the ignition switch off, so take care
not to short the removed cable to chassis ground.

• Connect the hand tester [A] and 12 V battery [B] to the

starter relay [C] as shown.
Special Tool - Hand Tester: 57001-1394
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Tester Range: × 1 Ω range
Criteria: When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω
16-52 ELECTRICAL SYSTEM
Electric Starter System
Electric Starter Circuit

1. Ignition Switch
2. Frame Ground
3. Water-proof Joint C
4. Starter Lockout Switch
5. Fuse Box
6. Ignition Fuse 10 A
7. Relay Box
8. Starter Circuit Relay
9. Main Fuse 30 A
10. Starter Relay
11. Starter Motor
12. Battery 12 V 10 Ah
13. Frame Ground
14. Sidestand Switch
15. Neutral Switch
16. Starter Button
17. Engine Stop Switch