Ignitioncoil

Ignitionswitch

Fuse(30A)

_{StarterrelayB/Y}

_Starter

^O/BGearpositionswitch

_I

(i\Clutchlever

~positionswitch

_BfW

_I

~

_button^Turnsignal/

side-standrelay

_{TROUBLESHOOTING}

(Startermotorwillnotrun.)

I

Thetransmissionisinneutral.Grasptheclutchlever,turnontheignitionswitchwiththeenginestopswitchinthe"RUN"positionandlistenforaclickfromthestarterrelaywhenthestarterbuttonispushed.

I

Noclick

Clicks

CheckifthestartermotorrunswhenitsterminalisconnectedtothebatteryG)terminal(Donotusethin''wire"becausealargeamountofcurrentflows)

II

_{RunsDoesnotrun}

l

•Faultystartermotor

Measurethestarterrelayvoltageatthe

starterrelayconnectors(betweenY/G8-Novoltage---•

_andB/Y¹³⁾_{whenthestarterbuttonis}

pushed.

Continuedonnextpage

T

•Faultystarterrelay

•Looseordisconnectedstartermotorleadwire

•Faultyignitionswitch

•Faultyenginestopswitch

•Faultyclutchleverpositionswitch

•Faultygearpositionswitch

•Faultyturnsignal/side-standrelay

•Faultystarterbutton

•Poorcontactofconnector

•Opencircuitinwireharness

Checkthestarterrelay.

_(CT7-13)

Nogood•Faultystarterrelay

_I

OK

_{-Poorcontactofthestarterrelay}

Thestartermotorrunswhenthetransmissionisinneutral,butdoesnotrunwhenthetransmissionisin

_{anypositionotherthanneutral,withtheside-standup.}

Checktheside-standswitch.

_(CT7-14)

^{1----Nogood----•}Faultyside-standswitch

IOK

(Others)

_-

Enginedoesnotturnthoughthestartermotorruns.

•Opencircuitinwireharness

•Poorcontactofconnector

•Faultystarterclutch

STARTERMOTORREMOVALANDDISASSEMBLY

•Removethestartermotor.

_{•Disassemblethestartermotorasshownintheillustration.}

G)O-ring

('iiHousingend(inside)

~~Startermotorcase

@:Armatura

·~Brushholderandspring

@Housingend(outside)

STARTERMOTORINSPECTION

CARBONBRUSH

Inspectthebrushesforabnormalwear,cracks,orsmoothnessinthebrushholder.

Ifanydamagesarefound,replacethebrushassemblywithanewone.

COMMUTATOR

Inspectthecommutatorfordiscoloration,abnormalwearorun•

dercut®·

Ifabnormalwearisfound,replacethearmaturewithanewone.Ifthecommutatorsurfaceisdiscolored,polishitwith#400sandpaperandwipeitusingacleandrycloth.

Ifthereisnoundercut,scrapeouttheinsulatorG)withasaw

_blade.

ARMATURECOILINSPECTION

Checkforcontinuitybetweeneachsegmentandbetweeneachsegmentandthearmatureshaftusingthemulticircuittester.

Ifthereisnocontinuitybetweenthesegmentsorthereisconti•nuitybetweenthesegmentsandshaft,replacethearmaturewithanewone.

tr'OOt!09900-25008:Multicircuittesterset

~~Testerknobindication:Continuitytest(•>>))

OILSEALINSPECTION

Checktheoilseallipfordamageorleakage.

Ifanydamageisfound,replacethehousingend.

STARTERMOTORREASSEMBLY

Reassemblethestartermotorinthereverseorderofdisassem•

bly.Payattentiontothefollowingpoints:

•Applygreasetothelipoftheoilseal.

~99000-25010:SUZUKISUPERGREASE"A"

_GJ

⁰

0

_\I'-.

^......

-.

ve,

•:~::::.:.·.·.•.•.•.••!•:c•••:~··

•ApplyasmallquantityofSUZUKIMOLYPASTEtothearrna•

tureshaft.

~99000-25140:SUZUKIMOLYPASTE

•AlignthematchmarksG)onthestartermotorcasewiththematchmarkonthehousingend.

•ApplyasmallquantityofTHREADLOCKSUPER"1322"tothestartermotorhousingbolts.

~99000-32110:THREADLOCKSUPER"1322"

•ApplySUZUKISUPERGREASE"A"tothe0-ring.

_,fu99000-2501O:SUZUKISUPERGREASE"A"

•Tightenthestartermotorleadwiremountingnuttothespeci•

fiedtorque.

~Leadwiremountingnut:5N·m(0.5kgf·m,3.5lb-ft)

STARTERRELAYINSPECTION

•Removethefrontseatandframecover.(c:::?'6-6)

•Disconnectthebattery8leadwirefromthebattery.

•Removethestarterrelaycover.

•DisconnectthestartermotorleadwireCD,batteryleadwire12}

andstarterrelaycoupler®·

•Removethestarterrelay©.

Apply12Vto®and®terminalsandcheckforcontinuitybe•tweenthepositiveandnegativeterminalsusingthemulticircuittester.Ifthestarterrelayclicksandcontinuityisfound,therelayisok.

11Qti09900-25008:Multicircuittesterset

~Testerknobindication:Continuitytest(•>)))

IACAUTIONI

Donotapplyabatteryvoltagetothestarterrelayformorethanfiveseconds,sincetherelaycoilmayover•heatanddamaged.

Measuretherelaycoilresistancebetweentheterminalsusingthemulticircuittester.Iftheresistanceisnotwithinthespecifiedvalue,replacethestarterrelaywithanewone.

1R%h09900-25008:Multicircuittesterset

D,Starterrelayresistance:3-5n

SIDESTAND/IGNITIONINTERLOCKSYSTEMPARTSINSPECTION

Checktheinterlocksystemforproperoperation.Iftheinterlocksystemdoesnotoperateproperly,checkeachcomponentfordamageorabnormalities.Ifanyabnormalityisfound,replacethecomponentwithanewone.

SIDE-STANDSWITCH

Theside-standswitchcouplerislocatedupperthecrankcase.

•Littthefueltank.(c::::;r4-52)

•Disconnecttheside-standswitchcouplerandmeasurethevoltagebetweenGreenandBlack/Whiteleadwires.

!T'OiK!09900-25008:Multicircuittesterset

_{:~Testerknobindication:Diodetest(~)}

_-----------

_Green

()

_lBlack/White

EBProbe

^(8Probe)

_ON

(Si

_up)

_0.4-0.6v

de-stand

_OFFMorethan1.4V

^{(Side-standdown)(}Tester'sbatteryvoltage)

NOTE:

Ifthetesterreadsunder1.4Vwhenthetesterprobesarenotconnected,replaceitsbattery.

GEARPOSITIONSWITCH

•Liftthefueltank.(c::::;r4-52)

•Disconnectthegearpositionswitchcouplerandcheckthecon•tinuitybetweenBlueandBlack/Whitewiththetransmissionin"NEUTRAL:'.

~	Blue	Black/White
ON(Neutral) OFF(Exceptneutral)	0	0

!ACAUTIONI

Whendisconnectingandconnectingthegearpositionswitchcoupler,makesuretoturnOFFtheignitionswitch,orelectronicpartsmaygetdamaged.

•Connectthegearpositionswitchcouplertothewiringharness.

•Turntheignitionswitchto"ON''positionandside-standtoup-rightposition.

MeasurethevoltagebetweenPinkandBlack/Whiteleadwires

usingamulticircuittester,whenshiftingthegearshiftleverfromlowtotop.

1.:&iL109900-25008:Multicircuittesterset

OWTesterknobindication:Voltage(::-:)

~Gearpositionswitchvoltage:Morethan0.6V

_{*Lowtotopgearposition)(Pink-B/W)}

⁽_{*Exceptneutralposition}

NOTE:

"Whenconnectingthemulticircuittester,installthecopperwire(ODisbelow0.5mm)tothebacksideoftheleadwirecouplerandconnecttheprobesoftestertothem.

..Usethecopperwire,itsouterdiameterisbelow0.5mm,to

preventtherubberofthewaterproofcouplerfromdamage.

TURNSIGNAUSIDE-STANDRELAY

Theturnsignal/side-standrelayiscomposedoftheturnsignalrelay,andtheside-standrelayanddiode.

•Removetheturnsignal/side-standrelay.

SIDE-STANDRELAYINSPECTION

Firstchecktheinsulationbetween@and~)terminalswiththetester.Thenapply12Vtoterminals©and:'©(©to©and8

to©)andcheckthecontinuitybetweenl]J1and~.Ifthereisnocontinuity,replacetheturnsignal/side-standrelaywithanewone.

(Q)©@®

®®©

r

--

_{SIDE-STANDRELAY}

_..---------

_D-IODE:TURN

_----.

_'^~·_SIGNAL

.o

^-o-,_RELAY

^{·-....------effi}

^®@©@®®©

DIODEINSPECTION

Measurethevoltagebetweentheterminalsusingthemulticircuittester.Refertothefollowingtable.

Unit:V

EBProbeoftesterto:

_r~I~[

_.^Q_o⁾_-⁰

0....

....(I)

_CL(j)

^©2

©,®

_®

^©,@®

©®@

_:w

1r'ixit109900-25008:Multicircuittesterset

Testerknobindication:Diodetest(-++)

NOTE:

Ifthemulticircuittesterreadsunder1.4Vwhenthetesterprobesarenotconnected,replaceitsbattery.

_{ELECTRICALSYSTEM7-17}