7-6
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to "CHECKING TH E FUSE" section in the CHAPTER 3.
*2 marked: Refer to "CHECKING AND CHARGIN G THE BATTERY" section in the CHAPTER 3.
*3 marked: Refer to "CHECKING THE MAIN SWITCH" section.
*4 marked: Refer to "CHECKING THE NEUTRAL SWITCH" section.
• Remove the following parts before inspection.
1. Seat
2. Rear fender
• Use 12 V battery in this inspection.
• Use the following special tools in this inspection.
*1 Check fuse. No good→Replace fuse and check wire harness.
OK ↓
*2 Check battery. No good→Recharge or replace.
OK ↓
Check each coupler and wire connection. No good →Repair or replace.
OK ↓
*3 Check main switch. No good→Replace.
OK ↓
Check starter motor operation. No good→Repair or replace.
OK ↓
Check starting circuit cut-off relay. No good→Replace.
OK ↓
Check starter relay. No good→Replace.
OK ↓
*4 Check neutral switch. No good→Replace.
OK ↓
Check clutch switch. No good→Replace.
OK ↓
Check diode. No good→Replace.
OK ↓
Check start switch. No good→Replace.
Pocket tester:
YU-3112-C/90890-03112
7-7
ELECTRIC STARTING SYSTEM
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:• Couplers and leads connection
Rust/dust/looseness/short-circuit
→ Repair or replace.
CHECKING THE STARTER
MOTOR OPERATION
1. Connect the posi tive battery ter-
minal "1" and starter motor lead
"2" with a jumper lead "3".
Not operate →Repair or replace
the starter motor.
• A wire that is used as a jumper lead must have at least the same
capacity or more as that of the
battery lead, otherwise the jump-
er lead may burn.
• This check is likely to produce
sparks, therefore make sure
nothing flammable is in the vicin-
ity.
CHECKING THE STARTING
CIRCUIT CUT-OFF RELAY
1. Remove:• Starting circuit cut-off relay
2. Inspect:
• Starting circuit cut-off relay con-duction
Use 12 V battery.
Not conductive while the battery is
connected →Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to " Ω
× 1".
CHECKING THE STARTER RELAY
1. Remove:
• Starter relay
2. Inspect: • Starter relay conduction
Use 12 V battery.
Not conductive while the battery is
connected →Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to " Ω
× 1".
CHECKING THE CLUTCH SWITCH
1. Inspect: • Clutch switch conduction
Not conductive while it is pulled →Re-
place.
Conductive while it is freed →Re-
place.
Set the tester selection position to " Ω
× 1".
CHECKING THE DIODE
1. Remove the diode from wire har-
ness.
2. Inspect: • Diode continuity
Use pocket tester (tester selec-
tion position Ω × 1)
Incorrect continuity →Replace.
CHECKING THE START SWITCH
1. Inspect: • Start switch conduction
Not conductive while it is pushed →
Replace.
Conductive while it is freed →Re-
place.
Set the tester selection position to " Ω
× 1".
Battery (+) lead →Blue/Black lead
"1"
Battery (-) lead →Brown lead "2"
Tester (+) lead →Blue/White lead
"3"
Tester (-) lead →Black lead "4"
Result Conductive (while the
battery is connected)
Battery (+) lead →Starter relay ter-
minal "1"
Battery (-) lead →Starter relay ter-
minal "2"
Tester (+) lead →Starter relay ter-
minal "3"
Tester (-) lead →Starter relay ter-
minal "4"
ResultConductive (while the
battery is connected)
Tester (+) lead →Black lead "1"
Tester (-) lead →Black lead "2"
Result Conductive (while the
clutch lever is pulled)
Tester (+) →Blue/Red
terminal "1"
Tester (-) →Sky blue
terminal "2" Continu-
ous
Tester (+) →Blue/Red
terminal "1"
Tester (-) →Blue/Yel-
low terminal "3" Continu-
ous
Tester (+) →Sky blue
terminal "2"
Tester (-) →Blue/Red
terminal "1" No con-
tinuous
Tester (+) →Blue/Yel-
low terminal "3"
Tester (-) →Blue/Red
terminal "1" No con-
tinuous
Tester (+) lead →Black lead "1"
Tester (-) lead →Black lead "2"
Result Conductive (while the
start switch is pushed)
