Category Archives: ANUAL SERVICE M
COMPONENT LOCATION
STARTER SWITCH
GENERAL
• 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.
ITEM |
SPECIFICATIONS |
Headlight |
12 V-35W |
Tail light |
LED |
Fuse |
15 A |
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 |
DUST COVER |
DUST COVER |
|
Remove the front visor.
— ’05 -’07: (page 3-5)
— After ’07: (page 3-6)
Remove the dust cover.
BULB SOCKET |
’05 — ’07 shown- |
|
While pushing the bulb socket, turn it counterclockwise and remove the bulb socket.
Remove the bulb.
Avoid touching the halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break.
’05 — ’07 shown: |
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 |
While 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!
REMOVAL/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
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.
|
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
|
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
© 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.
|
4PCONNECTOR |
Remove the left side cover (page 3-3).
|
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.
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 |
|
WASHER |
|
O-RING ^ |
Install the following: — Insulator — Terminal bolt |
— New O-ring — Insulators — Washer — Nut |
— Insulator plates
SCREWS/BRUSH/WASHERS |
|
INSULATOR PLATES |
|
— Brush holder
— Washers
— Brush
— Screws
— Brush springs
SPRINGS |
BRUSH
ARMATURE |
BRUSHES |
|
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 |
|
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.
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 |
|
SEAL RING |
INSULATED WASHER |
FRONT COVER |
|
Install the washer by aligning its tabs to the front cover grooves.
FRONT COVER |
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.
|
Tighten the motor case bolts to the specified torque.
BOLTS |
|
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)
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).
STARTER MOTOR |
BOLTS — Я RUBBER CAP
STARTER MOTOR
• 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
Remove the O-ring.
|
O-RING |
|
Remove the motor case bolts.
Record the location and number of shims. |
|
SEAL RING SHIMS |
FRONT COVER |
|
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 _
|
r |
sh, ms. SHIMS
|
Remove the brush springs.
і
SPRINGS |
BRUSH
Check for continuity between the cable terminal and.
insulated brush. Continuity:
There should be continuity.
|
Continuity: |
Check for continuity between the cable terminal and rear cover. N°
I |
There should be no continuity.
|
Remove the following:
SCREWS/BRUSH/WASHERS |
BRUSH HOLDER INSULATOR PLATES |
|
— Screws
— Brush
— Washers
— Brush holder
— Insulator plates
|
— Nut
Record the location and number of insulators. |
— Washer
— Insulators
— O-ring
— Terminal bolt/insulator
TERMINAL BOLT/INSULATOR
INSULATORS
WASHER |
|
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 ARMATURE |
the commutator.
COMMUTATOR BARS |
|
Continuity: |
Check for continuity between pairs of commutator bars.
There should be continuity.
ARMATURE SHAFT |
Continuity: |
COMMUTATOR BAR |
|
Check for continuity between each commutator bar and armature shaft.
There should be no continuity.