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



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



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


r-------I.... Loose or poor contact of the starter relay switch

Normal connector

Abnormal

'--------------------. Faulty starter relay switch(

16-3



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


.. Burnt bulb


• Faulty clutch switch



• Loose or poor contact of connector

16-4



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



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



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



MEMO

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CB500R Workshop Manual 16 Electric Starter