Monthly Archives: Март 2014

COMPONENT LOCATION

STARTER SWITCH

SERVICE INFORMATION

GENERAL

NOTICE

• A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing.

• Note the following when replacing the halogen headlight bulb.

— Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause is to fail.

— If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent its early failure.

— Be sure to install the dust cover after replacing the bulb.

• Check the battery condition before performing any inspection that requires proper battery voltage.

• A continuity test can be made with the switches installed on the motorcycle.

SPECIFICATIONS

ITEM

SPECIFICATIONS

Headlight

12 V-35W

Tail light

LED

Fuse

15 A

TORQUE VALUES

0.7 N m (0.1 kgf-m, 0.5 Ibf ft) 4.2 N-m (0.4 kgf-m, 3.1 Ibf ft) 0.7 N-m (0.1 kgf-m, 0.5 Ibf-ft)

Headlight mounting screw Tail light mounting screw Tail light wire clamp screw

HEADLIGHT

BULB REPLACEMENT

DUST COVER

DUST COVER

COMPONENT LOCATION

Remove the front visor.

— ’05 -’07: (page 3-5)

— After ’07: (page 3-6)

Remove the dust cover.

BULB SOCKET

’05 — ’07 shown-

COMPONENT LOCATION

While pushing the bulb socket, turn it counterclock­wise and remove the bulb socket.

Remove the bulb.

NOTICE

Avoid touching the halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break.

’05 — ’07 shown:

COMPONENT LOCATION

Install a new bulb into the headlight unit while aligning the tab with the groove of the headlight unit.

If you touch the bulb with your bare hands, clean it with a cloth moistened with denatured alcohol to prevent early bulb failure.

05 — ’07 shown

COMPONENT LOCATIONWhile pushing the bulb socket, turn it clockwise and install the bulb socket.

BULB SOCKET

TOP" MARK

Install the dust cover tightly against the headlight unit with its "TOP" mark facing up.

Install the front visor.

— ’05-’07: (page 3-5)

— After ’07: (page 3-6)

DUST COVER

"TOP" MARK

DUST COVER

ADJUSTING SCREW/ SPRING

CLAMP

MOUNTING

SCREWS

REMOVAL/INSTALLATION (’05 — ’07)

Remove the front visor (page 3-5).

Remove the vertical beam adjusting screw, spring, mounting screws, clamp and headlight unit.

Installation is in the reverse order of removal.

TORQUE:

Headlight mounting screw:

0.7 N-m (0.1 kgf m, 0.5 Ibf ft)

Adjust the headlight aim (page 4-31).

HEADLIGHT UNIT!

COMPONENT LOCATIONREMOVAL/INSTALLATION (After ’07)

MOUNTING SCREWS

ADJUSTING SCREW/ SPRING

Remove the front visor (page 3-6).

Remove the vertical beam adjusting screw, spring, mounting screws and headlight unit.

Installation is in the reverse order of removal.

TORQUE:

Headlight mounting screw:

0. 7 N m (0.1 kgf m, 0.5 Ibf ft)

Adjust the headlight aim (page 4-31).

HEADLIGHT UNIT

STARTER RELAY SWITCH

INSPECTION

STARTER RELAY SWITCH

STARTER RELAY SWITCH

Remove the left side cover (page 3-3).

Shift the transmission into neutral.

Pull the clutch lever fully, and push the engine starter switch.

If the starter relay switch "CLICK", the coil is normal.

If you don’t hear the switch "CLICK", inspect the starter relay switch using the procedure below.

STARTER RELAY SWITCH

4P CONNECTOR

GROUND LINE

Disconnect the starter relay switch 4P connector.

Check for continuity between the Green wire termi­nal of the wire harness side connector and ground.

If there is continuity, the ground circuit is normal.

POWER INPUT LINE

STARTER RELAY SWITCH

4PCONNECTOR

Connect the starter relay switch 4P connector.

Shift the transmission into neutral.

Pull the clutch lever fully, and push the starter switch.

Measure the voltage between the Yellow/red wire terminal (+) and ground (-).

If the battery voltage appears only when the clutch lever is pulled fully and starter switch is pushed, the circuit is normal.

OPERATION CHECK

STARTER RELAY SWITCH

© 0 BATTERY

Remove the starter relay switch (page 19-14).

Connect a fully charged 12 V battery positive wire to the relay switch Yellow/red wire terminal and the negative wire to the Green wire terminal.

There should be continuity between the cable termi­nals when the battery is connected, and not continu­ity when the battery is disconnected.

STARTER RELAY SWITCH

4PCONNECTOR

REMOVAL/INSTALLATION

Remove the left side cover (page 3-3).

STARTER RELAY SWITCH

STARTER RELAY SWITCH

Disconnect the starter relay switch 4P connector. Pull out the starter relay switch from the rear fender.

Remove the bolts and disconnect the starter motor and battery positive (+) cables.

Installation is in the reverse order of removal.

LIGHTS/METER/SWITCHES

ASSEMBLY

O-RING

DUST SEAL WASHER

INSULATED WASHER

SHIM ARMATURE

BRUSH

FRONT COVER

SEAL RINGS

SHIMS

BRUSH SPRING

WASHER

INSULATORS

O-RING

MOTOR CASE

BRUSH HOLDER INSULATOR TERMINAL BOLT

INSULATOR PLATE

REAR COVER

3.4 N m (0.3 kgf-m, 2.5 Ibf-ft)

INSULATOR

TERMINAL BOLT INSULATORS

ASSEMBLY

WASHER

ASSEMBLY

O-RING ^

Install the following:

— Insulator

— Terminal bolt

— New O-ring

— Insulators

— Washer

— Nut

— Insulator plates

SCREWS/BRUSH/WASHERS

ASSEMBLY

INSULATOR PLATES

ASSEMBLY

— Brush holder

— Washers

— Brush

— Screws

— Brush springs

ASSEMBLY

SPRINGS

BRUSH

ARMATURE

BRUSHES

ASSEMBLY

Apply grease to the armature shaft end.

Install the shims properly as noted during removal.

Install the shims onto the armature shaft.

Install the armature onto the rear cover while push­ing the brushes into the brush holder.

Align the motor case groove to the insulator tab.

MOTOR CASE

REAR COVER

ARMATURE

ASSEMBLY

Install a new seal ring and motor case to the rear cover while holding the armature tightly to keep the magnet of the case from pulling the armature against it.

NOTICE

The coil may be damaged if the magnet pulls the armature against the case.

Apply grease to the oil seal lip and needle bearing in the front cover.

WASHER

ASSEMBLY

SEAL RING

INSULATED WASHER

FRONT COVER

ASSEMBLY

Install the washer by aligning its tabs to the front cover grooves.

FRONT COVER

ASSEMBLY

Install the shims Install the shims and insulated washer onto the properly as noted armature shaft. during removal. Install a new seal ring onto the motor case.

Install the front cover being careful not to damage the oil seal lip.

ASSEMBLY

Tighten the motor case bolts to the specified torque.

BOLTS

ASSEMBLY

ASSEMBLY

Coat a new O-ring with oil and install it into the starter motor groove.

TORQUE: 3.4 N m (0.3 kgf m, 2.5 Ibf-ft)

INSTALLATION

STARTER MOTOR CABLE

Install the starter motor onto the crankcase.

Install and tighten the starter motor mounting bolt. Install the starter motor cable and terminal nut onto the motor terminal.

Tighten the nut securely.

Install the rubber cap over the motor terminal prop­erly.

Install the cylinder (page 10-10).

ASSEMBLY

ASSEMBLY

STARTER MOTOR

BOLTS — Я RUBBER CAP

STARTER MOTOR

REMOVAL

• Remove the negative cable at the battery before servicing the starter motor.

STARTER MOTOR CABLE

Remove the cylinder (page 10-5).

Remove the rubber cap from the starter motor ter­minal.

Remove the nut and disconnect the starter motor cable.

Remove the mounting bolts, and starter motor from the crankcase.

RUBBER CAP

DISASSEMBLY/INSPECTION

Remove the O-ring.

STARTER MOTOR

O-RING

STARTER MOTOR

Remove the motor case bolts.

Record the location and number of shims.

STARTER MOTOR

SEAL RING

SHIMS

FRONT COVER

STARTER MOTOR

WASHER

BOLTS

Remove the following:

— Front cover

— Insulated washer

— Shims

— Seal rings

— Washer

— Motor case

— Armature

MOTOR CASE | ARMATURE INSULATED WASHER

Record the location Remove the shims.

and number of _

STARTER MOTOR

r

sh, ms. SHIMS

STARTER MOTOR

Remove the brush springs.

і

STARTER MOTOR

SPRINGS

BRUSH

Check for continuity between the cable terminal and.

insulated brush. Continuity:

There should be continuity.

STARTER MOTOR

Continuity:

Check for continuity between the cable terminal and rear cover. N°

I

There should be no continuity.

STARTER MOTOR

Remove the following:

SCREWS/BRUSH/WASHERS

BRUSH HOLDER INSULATOR PLATES

STARTER MOTOR

— Screws

— Brush

— Washers

— Brush holder

— Insulator plates

STARTER MOTOR

— Nut

Record the location and number of insulators.

— Washer

— Insulators

— O-ring

— Terminal bolt/insulator

TERMINAL BOLT/INSULATOR

INSULATORS

WASHER

STARTER MOTOR

O-RING

Measure the brush length. SERVICE LIMIT: 6.75 mm (0.266 in)

Do not use emery Inspect the commutator bars of the armature for or sand paper on discoloration.

COMMUTATOR BARS

STARTER MOTOR

ARMATURE

the commutator.

COMMUTATOR BARS

STARTER MOTOR

Continuity:

Check for continuity between pairs of commutator bars.

There should be continuity.

ARMATURE SHAFT

Continuity:

COMMUTATOR BAR

STARTER MOTOR

Check for continuity between each commutator bar and armature shaft.

There should be no continuity.