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

TORQUE VALUES

HEADLIGHT

BULB REPLACEMENT

Remove the front visor.

— ’05 -’07: (page 3-5)

— After ’07: (page 3-6)

Remove the dust cover.

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.

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.

While pushing the bulb socket, turn it clockwise and install the bulb socket.

BULB SOCKET

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

HEADLIGHT UNIT!

REMOVAL/INSTALLATION (After ’07)

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

INSPECTION

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.

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

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

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.

REMOVAL/INSTALLATION

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

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

DUST SEAL WASHER

INSULATED WASHER

SHIM ARMATURE

FRONT COVER

BRUSH SPRING

WASHER

INSULATORS

O-RING

BRUSH HOLDER INSULATOR TERMINAL BOLT

INSULATOR PLATE

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

— Insulator plates

— Brush holder

— Washers

— Brush

— Screws

— Brush springs

BRUSH

Apply grease to the armature shaft end.

Install the shims onto the armature shaft.

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

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.

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

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.

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

INSTALLATION

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).

BOLTS — Я RUBBER CAP

REMOVAL

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

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.

Remove the motor case bolts.

Record the location Remove the shims.

and number of _

sh, ms. SHIMS

Remove the brush springs.

і

BRUSH

Check for continuity between the cable terminal and.

insulated brush. Continuity:

There should be continuity.

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

There should be no continuity.

Remove the following:

— Screws

— Brush

— Washers

— Brush holder

— Insulator plates

— Nut

— Washer

— Insulators

— O-ring

— Terminal bolt/insulator

TERMINAL BOLT/INSULATOR

INSULATORS

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.

the commutator.

Check for continuity between pairs of commutator bars.

There should be continuity.

Check for continuity between each commutator bar and armature shaft.

There should be no continuity.