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.
Voltage check
If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
With all connectors/couplers connected and voltage
applied to the circuit being checked, measure
voltage between each terminal and body ground.
If measurements were taken as shown ...
License plate light bulb replacement
Caution
when you touch the bulb with your bare
hands, clean the bulb with a cloth moistened
with alcohol or soap water to prevent
premature bulb failure.
Remove the license plate light mounting nuts.
Remove the lens cover (1) by removing the screws.
Re ...
Engine bottom side disassembly
Note
the crankcase must be separated to service
the crankshaft and conrod.
Remove the engine assembly from the frame. Refer to “engine assembly
removal” .
Remove the engine top side (1). Refer to “engine top side disassembly”
.
Crankcase breather (pcv) cover
R ...