Refer to “starter motor disassembly and assembly” .
Carbon brush
Inspect the carbon brushes for abnormal wear, cracks or smoothness in the brush holder.
If either carbon brush is defective, replace the brush holder set with a new one.
Measure the length “a” of the carbon brushes using a vernier calipers. If the measurement is less than the service limit, replace the housing end assembly (outside) with a new one.
Brush length “a” service limit: 3.5 Mm (0.14 In)
Special tool
: 09900–20102 (vernier calipers
(200 mm))
Commutator
Inspect the commutator for discoloration, abnormal wear or undercut “a”.
If the commutator is abnormally worn, replace the armature assembly.
If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator (1) with a saw blade.
Armature coil
Inspect for continuity between each segment.
Inspect for continuity between each segment and the armature shaft.
If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature assembly with a new one.
Special tool
(a): 09900–25008 (multi circuit
tester set)
Tester knob indication
continuity set ( )
Bearing
Check the bearings for damage.
If any damage is found, replace the housing end.
Oil seal
Check the seal lip for damage.
If any damage is found, replace the housing end.
Body frame construction
Frame
Seat rail
Seat rail bolt
Collar
Engine mounting thrust adjuster
Engine mounting thrust adjuster lock-nut
Engine mounting pinch bolt
50 N·m (5.0 Kgf-m,
36.0 Lbf-ft)
23 N·m
(2.3 Kgf-m, 16.5 Lbf-ft)
45 N·m
(4.5 Kgf-m, 32. ...
Handlebar components
Throttle grip
Grip rubber
Right handlebar switch box
Left handlebar switch box
Right handlebar
Left handlebar
Handlebar expander
Handlebar balancer
Apply handle grip bond.
23
N·m (2.3 Kgf-m, 16.5 Lbf-ft)
5.5 N·m
(0.55 Kgf-m, 4.0 L ...
Fuel tank construction
Fuel tank heat
shield
: aluminum film side should face the engine side.
Fuel tank front cover
Fuel tank front bracket
Velcro fastenings
: clean the adhesive surface before adhering
the velcro fastenings.
Insert
to the bracket.
Apply
...