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.
Special tools and equipment
Recommended service material
Note
required service material is also described in the following.
“Clutch control system components” “clutch components”
Special tool
...
Throtile cable play
This motorcycle has a twin throttle
cable system. Cable A is for pulling
cable and cable B is for
returning.
To adjust the cable play:
Loosen the lock nut 1.
Turn the adjuster 2 so that the
throttle grip has 2.0 - 4.0 Mm
(0.08- 0.16 In) play.Tighten the lock nut 1.
...
Engine coolant recommendation
Engine coolant
Use an anti-freeze/engine coolant compatible with an
aluminum radiator, mixed with distilled water only.
Water for mixing
Use distilled water only. Water other than distilled water
can corrode and clog the aluminum radiator.
Anti-freeze / engine coolant
The engine coolant perfo ...