5 SPECIFICATIONS STARTER SERVICE WEAR LIMITS IN. MM Free speed 3000 RPM (min.) @ 11.5 V Brush length minimum 0.433 11.0 Free current 90 amp (max.) @ 11.5 V 1.141 28.98 Stall current 400 amp (max.) @ 2.4 V Commutator diameter minimum Stall torque 8.1 ft-lbs (11.0 Nm) (min.) @ 2.4 V ITEM TORQUE Battery terminal hardware 30-40 in-lbs 3.4-4.5 Nm Starter mounting bolts 13-20 ft-lbs 17.6-27.
ELECTRIC STARTER SYSTEM GENERAL The starter is made up of an armature, field winding assembly, solenoid, drive assembly, idler gear and drive housing. The starter motor torque is increased through gear reduction. The gear reduction consists of the drive pinion on the armature, an idler gear and a clutch gear in the drive housing. The idler gear is supported by rollers. The clutch gear is part of the overrunning clutch/drive assembly.
b0164x5x Armature STARTER AT MOMENT STARTER SWITCH IS CLOSED Field winding Brush Idler gear Pinion gear Ball bearing Plunger Main contacts Overrunning clutch Hold-in winding Pull-in winding Battery Start circuit – See wiring diagram Clutch ring gear Armature STARTER DURING CRANKING Field winding Brush Idler gear Pinion gear Ball bearing Plunger Main contacts Overrunning clutch Clutch ring gear Hold-in winding Pull-in winding Battery Start circuit – See wiring diagram Figure 5-1.
5-4 b0207x5x TN O NEUTRAL TN P1 IGN POWER BE TO STARTER Y/O GY 1 2 3 4 BK/R NEUTRAL SWITCH P3 O TN 12 11 10 9 8 7 6 5 4 3 2 1 BK P14 TN/W 2 1 BK W S2 SIDE STAND SWITCH S1 TN S13 S11 TN/GN MAIN CHASSIS GROUND S12 TN S10 TN/GN R TN/GN BK MASTER 30A CIRCUIT BREAKER S7 TN/GN S15 R GN TN/W GY P13 TN/W P8 VIEW FROM FUSE INSERTION SIDE P12 TN/GN BK/R R CLUTCH SWITCH A B C D TN/GN BK R/B K 1 2 R/BK S14 P5 FROM IGN RLY R/BE TO GROUND BK GN BK BK IGNITION GY/O 15A LT
Table 5-1. Troubleshooting PROBLEM 1. Starter does not run or runs at very low speeds. SOURCE OF PROBLEM 1.1 Battery. PROBABLE CAUSE SOLUTION 1.1.1 Voltage drop due to discharged battery. 1.1.1 Charge battery. 1.1.2 Short-circuited or open between electrodes. 1.1.2 Replace battery. 1.1.3 Poor contact condition of battery terminal(s). 1.1.3 Clean and retighten. 1.2 Wiring. 1.2.1 Disconnection between starter switch and solenoid terminal. 1.2.1 Repair or replace wire. 1.
Table 5-1. Troubleshooting (Continued) PROBLEM 2. 3. Pinion does not engage with ring gear while starter is running or engine cannot be cranked. Starter does not stop running. SOURCE OF PROBLEM 2.1 Battery. SOLUTION 2.1.1 Voltage drop due to discharged battery. 2.1.1 Charge battery. 2.1.2 Short-circuited or open between electrodes. 2.1.2 Replace battery. 2.1.3 Poor contact condition of battery terminal(s). 2.1.3 Clean and retighten. 2.2 Wiring. 2.2.
BATTERY TESTS • Visual • Voltage Check connections at battery and starter components INOPERATIVE Nothing clicks Test relay Check for power at relay from button NO Relay clicks Test wiring to relay and solenoid Solenoid clicks Perform voltage drop tests between battery and solenoid relay terminals (less than 1 volt) High voltage Check for power at button NO Check for power to button Sticky starter button YES Test solenoid Check for ground at relay YES NO YES Test starter motor Correct re
STARTER ACTIVATION CIRCUITS b0157x5x ITEM A Start switch 0.1A 0.1A 0.1A 20A Ignition circuit breaker Ignition switch 20A Main circuit breaker VDC 150A Relay Ignition switch OV Main circuit breaker VDC 150A Solenoid Battery 0.1A 20A Ignition circuit breaker Relay ITEM B Start switch 20A 150A Starter 150A Solenoid Battery Starter IDEAL CLOSED CIRCUIT ITEM C Start switch 0.1A Ignition circuit breaker Ignition switch Main circuit breaker 0.
DIAGNOSTICS/TROUBLESHOOTING GENERAL The TROUBLESHOOTING table, starting on page 5-5, contains detailed procedures to solve and correct problems. Follow the ELECTRIC STARTING SYSTEM DIAGNOSIS diagram on page 5-7 to diagnose starting system problems. The VOLTAGE DROPS procedure below will help you to locate poor connections or components with excessive voltage drops. 7. If the voltage drop is greater, back track through the connections until the source of the potential difference is found.
STARTER SYSTEM TESTING “ON-MOTORCYCLE” TESTS b0208x5x Starter Relay Test 1. See Figure 5-5. Locate starter relay. The relay is attached to the frame near the oil tank’s feed hose. Unplug relay connector. 2. To test relay, proceed to Step 3. If installing a new starter relay, remove old relay. Secure new relay to frame using screw and washer. Attach relay connector plug. 3. See Figure 5-6. Obtain a 12 volt battery and a continuity tester or ohmmeter. Connect positive battery lead to the 86 terminal.
STARTER REMOVAL 1WARNING To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before performing any of the following procedures. Always disconnect the negative cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury. 1CAUTION Hold battery cable when loosening battery terminal hardware. Failure to hold cable will cause battery damage. 1.
