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18. STARTING SYSTEM

18-0

MXU 250

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STARTING SYSTEM

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SERVICE INFORMATION------------------------------------------------ 18- 2

TROUBLESHOOTING----------------------------------------------------- 18- 2

STARTER MOTOR --------------------------------------------------------- 18- 3

STARTER RELAY---------------------------------------------------------- 18- 7

STARTER CLUTCH-------------------------------------------------------- 18- 8

RECOIL STARTER --------------------------------------------------------- 18-10

Summary of content (12 pages)

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8.
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18.
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18. STARTING SYSTEM MXU 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed.
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18. STARTING SYSTEM STARTER MOTOR MXU 250 Rubber Jacket Bolts REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly. Remove the waterproof rubber jacket and remove nut to disconnect the starter motor cable connector. Remove the two starter motor mounting bolts and the motor.
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18. STARTING SYSTEM MXU 250 Check for continuity between pairs of the commutator segments and there should be continuity. Also, make a continuity check between individual commutator segments and the armature shaft. There should be no continuity. STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary.
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18. STARTING SYSTEM MXU 250 Check for continuity between the brushes. If there is continuity, replace with new ones. Bearing Check if the needle bearing in the front cover turns freely and has no excessive play. Replace if necessary. Check the dust seal for wear or damage. Dust Seal Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft.
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18. STARTING SYSTEM MXU 250 Tab Groove Install a new O-ring to the front cover. Install the starter motor case, aligning the tab on the motor case with the groove on the front cover. Tighten the starter motor case screws. ＊ When assembling the front cover and motor case, slightly press down the armature shaft to assemble them. Motor Case STARTER MOTOR INSTALLATION Connect the starter motor cable connector and properly install the waterproof rubber jacket.
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18. STARTING SYSTEM MXU 250 Starter Relay STARTER RELAY INSPECTION Remove the seat. (Refer to the chapter 2) Turn the ignition switch ON and the starter relay is normal if you hear a click when the starter button is depressed.
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18. STARTING SYSTEM MXU 250 STARTER CLUTCH REMOVAL Remove the right crankcase cover. (Refer to the “WATER PUMP SHAFT REMOVAL” section in the chapter 12) Remove the flywheel. (Refer to the “A.C. GENERATOR/FLYWHEEL REMOVAL” section in the chapter 16) Inspect the starter one-way clutch for wear or damage. Starter One-way Clutch Remove the starter driven gear. Starter Driven Gear Inspect the starter driven gear for wear or damage.
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18. STARTING SYSTEM MXU 250 Starter Idle Gear Shaft Remove the starter idle gear and shaft. Starter Idle Gear Starter Idle Gear Inspect the starter idle gear and shaft for wear or damage. Starter Idle Gear Shaft INSTALLATION Reverse the “REMOVAL” procedures. Install the starter idle gear and shaft. Install the starter driven gear. Install flywheel and right crankcase cover. (Refer to the “A.C.
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18. STARTING SYSTEM MXU 250 Recoil Starter RECOIL STARTER Refer to the chapter 9 to remove recoil starter. ＊ Do not disassembly that the recoil starter would not be assembly. ROPE REPLACE Insert the rope into the hook part of the friction plate, reel the rope clockwise five times with the rope, then cut the rope. Rope Hook the rope onto the groove of the recoil starter case. Plug Remove the plug of the recoil starter grip.
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18. STARTING SYSTEM Insert the rope into recoil starter grip and washer. MXU 250 Washer Reinstall the cap. Pull the rope and check that the ratchet is pushed out Refer to the chapter 9 to remove ratchet. Inspect the ratchet splines. Wear/damage → Replace.