Download - CB500R Workshop Manual 16 Electric Starter
8/8/2019 CB500R Workshop Manual 16 Electric Starter
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1 6. E le ctr ic S ta rte r
Service Information 16-1
16-2
16-3
Starter Motor Removal/lnstalJation
Starter Motor Disassembly/Assembly
Starter Clutch Removal/Installation
16-5
16-6
16-7
System Location
Troubleshooting
S e r v i c e I n f o r m a t i o n
• Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing
serious injury.
• A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
• If the current is kept flowing through the starter motor turn it while the engine is not cranking over, the starter motor may
be damaged.
• For the following component inspections, refer to the following pages; for the parts locations, see page 16-2 of this
manual (System Location).
Clutch switch diode Section 24 of the Common Service Manual
Starter motor Section 24 of the Common Service Manual
Starter relay switch Section 24 of the Common Service Manual ("A" circuit type)
Clutch switch Section 25 ofthe Common Service Manual
Neutral switch Section 25 ofthe Common Service Manual
Ignition switch Check for continuity on the continuity chart of the Wiri ng Diagram, section 18.
Disconnect the switch connector inside the headlight case (page 1-23) and check it.
Side stand switch Section 25 of the Common Service Manual IE
16-1
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Electric Starter
S y s t e m L o c a t i o n
(14) STARTER MOTOR
(10) STARTER RELAY SWITCH
(11) MAIN FUSE 30A
(2) SIDE STAND
INDICATOR
(1) .CLUTCH
SWITCH
\
(13) NEUTRAL SWITCH
(12) SIDE STAND
SWITCH
(14) STARTER MOTOR
0 : : 0 : :
<, <, 0 : : RI W -+ (15) REGULATOR/RECTIFIER(!)-~ .
[
(4) IGNITION RI B 1 2 1SWITCH lOA 15A
D"o- B 1 IW -o~ B 1(6) STARTER (5) ENGINE STOP B 1IB
SWITCH SWITCH r
BI ••••••• Black
Y •••••••• Yellow
G •••••••• Green
R •••••••• R ed
W·······WhiteBr ••••••• Brown
Lg ••••••• Light green
(3) NEUTRAL INDICATOR
(7) DIODE 1 Ma : : : e n <,
<, _j e n
(!) _j
'---11-------- G/ R ~ GI W
(1) CLUTCH SWITCH .--+-..,
(2) SIDE STAND
INDICATOR
(13) NEUTRAL SWITCH
(12) SIDE STAND
SWITCH
16-2
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Electric Starter
T r o u b l e s h o o t i n g(
( srter M otor W ill N ot Turn
'. - Check for a blown main or sub fuse before servicing .
• Make sure the battery is fully charged and in good condition.
NOTE:
• The starter motor does not turn when the engine stop switch is OFF.
Check for loose or poorly connected battery
terminals, and opened or shorted battery cable,
Normal
Check for loose or poorly connected starter relay
switch terminals and 4P connector.
Normal
JCheck for loose or poorly connected startermotor cable, and opened cable.
L~ __~ -. ~~
Normal
With the ignition switch ON and the engine stop
switch at RUN, push the starter switch and check
for aI/click" sound from the starter relay switch.
No click
Disconnect starter relay switch connector, and
check the relay coil ground wire lines as follows
for continuity:
,. Green/Red terminal-clutch switch diode-
neutral switch line (with transmission in
neutral and clutch lever released.)
2. Green/Red terminal-clutch switch-side stand
switch line (in any gear except neutral, and
with the clutch lever pulled in and the side
stand up.)
Continuity
Connect the starter relay switch connector. With
the ignition switch ON, engine stop switch RUN
and the starter switch pushed, measure the
starter relay voltage at the starter switch
connector (between Yellow/Red (+ ) and ground
(-)).
Voltage Appeared
Check the starter relay switch operation.
f-------1J-.Poorly connected battery terminals
Abnormal • Open or short circuit in battery cable
f------1J-. Poorly connected terminals or 4P connector
Abnormal
f----~-. Poorly connected motor cableAbnormal • Open circuit in motor cable
Connect the starter motor termi nal to the battery
positive terminal directly. (Because a large
amount of current flows, do not use thin wires).Clicks
St~rter
motor
turns
~
Sta~er motor
does not turn,• Faulty starter motor
• Loose or disconnected starter motor cable
• Faulty starter relay switch
f----__,-. Faulty neutral switch
No continuity. Faulty clutch switch diode
• Faulty clutch switch
• Faulty side stand switch
• Loose or poor contact of connector
• Open circuit in wire harness
f----__,,-. Faulty ingition switch
No voltage • Faulty starter switch
• Faulty engine stop switch
• Blown out main or sub fuses
• Loose or poor contact or connector
• Open circuit in wire harness
r-------I.... Loose or poor contact of the starter relay switch
Normal connector
Abnormal
'--------------------. Faulty starter relay switch(
16-3
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Electric Starter
The starter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except
neutral, with the side stand up and the clutch lever pulled in.
Check that the side stand indicator operates
properly with the ignition switch ON. Abnormal
Normal
Check the clutch switch operation.
Abnormal
Normal
Check the side stand switch.
Abnormal
Normal
Starter Motor Turns Slowly
• Low specific gravity in battery (or Dead battery)
• Poorly connected battery terminal cable
• Poorly connected starter motor cable
• Faulty starter motor
• Poorly connected battery ground cable
Starter Motor Turns, but Engine Does Not Turn
• Starter motor is running backwards
- Case assembled improperly
-Terminals connected improperly
• Faulty starter clutch
• Damaged or faulty starter pinion
• Damaged reduction gears
Starter Relay Switch "Click", but Engine Does Not Turn Over
• Crankshaft does not turn due to engine problems
• Excessive reduction gear friction
• Faulty side stand switch
.. Burnt bulb
• Open circuit in wire harness
• Faulty clutch switch
• Faulty side stand switch
• Open circuit in wire harness
• Loose or poor contact of connector
16-4
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Electric Starter
S t a r t e r M a t e r R e m o v a l / I n s t a ll a t i o n
(3)
(4 )
~~~........I(6)
(5)
NOTE:
With the ignition switch OFF, remove the ground cable at the battery before servicing the starter motor.
(1)
(2)
(3)
(4) i(5) ,
, II (6) I
Procedure Q'ty Remarks
Removal Order
Terminal nut
Starter motor cable
Starter motor mounting bolt
Ground cable
Starter motor assembly
O-ring
Installation is in the reverse order of removal.
1,2
IDisasembly/assembly (page 16-6)
16-5
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Electric Starter
S t a r t e r M o t o r D i s a s s e m b l y /A s s e m b l y
(1)
(4)
~(5)
(9)
(8)
/~,
(10)
(7)
~e (6)
Requisite Service
• Starter motor removal/installation (page 16-5)
Procedure Q'ty I Remarks
I Disassembly Order Assembly is in the reverse order of disassembly.
(1) Starter motor cover bolt 2
(2) Front cover 1
(3) Packing 1
(4) Lockwasher 1
(5) Shim _-r- Record and store the shims in the same order they were
Iinstalled so they can be reinstalled in the original
positions.
(6) Rear cover
l J I(7) Packing
(8) Shim
(9) Armature 1 I
(10) Brush holder assembly 1I
16-6
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Electric Starter
S t a r t e r C l u t c h R e m o v a l / I n s t a l l a t i o n
.;:.'~- .-~--.
(3),
~~(4)
~~ '\ 030 (3.0,22)
CW [STOOLl(page 1-19)
Requisite Service
• Flywheel removal/installation (page 14-8)
.>
,
Q'ty IProcedure Remarks
Removal Order
!Installation is in the reverse order of removal.
(1 ) Starter driven gear 1
(2) Starter drive gear 1
(3) Drive gear shaft 1
(4 ) One-way clutch bolt 6
(5) Starter clutch housing 1
(6) Starter one-way clutch 1I
16-7
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