User Guide

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18. STARTING SYSTEM

18-0

YUP 25 0

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STARTING SYSTEM

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STARTING SYSTEM LAYOUT -------------------------------------- 18-1

SERVICE INFORMATION -------------------------------------------- 18-2

TROUBLESHOOTING ------------------------------------------------- 18-2

STARTER MOTOR ----------------------------------------------------- 18-3

STARTER CLUTCH INSPECTION----------------------------------- 18-5

STARTER RELAY INSPECTION ------------------------------------ 18-6

Summary of content (8 pages)

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8.
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18.
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18. STARTING SYSTEM YUP 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 10-3. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system. SPECIFICATIONS Item Starter motor brush length TORQUE VALUES Starter motor mounting bolt Starter motor case screw Starter clutch bolt 6.7_ 2.9_ 9.
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18. STARTING SYSTEM STARTER MOTOR YUP 250 Starter Motor Cable Rubber Sheath REMOVAL ＊ • Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly. Remove the met-in box. (!2-6) Remove the air cleaner. (!5-1) Nut Remove rubber sheath of starter motor lead. Remove the nut from the starter motor cable and disconnect the starter motor cable.
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18. STARTING SYSTEM DISASSEMBLY Remove the two starter motor case screws, front cover, rear cover, motor case and other parts. YUP 250 Motor Case Front Cover Case Screws INSPECTION Inspect the removed parts for wear, damage or discoloration. Replace if necessary. Clean the commutator if there is metal powder between the segments. Commutator Check for continuity between pairs of the commutator segments and there should be continuity.
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18. STARTING SYSTEM YUP 250 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary. Wire Terminal Measure the length of the brushes. Service Limit: 8.5mm replace if below Check for continuity between the brushes. If there is continuity, replace with new ones.
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18. STARTING SYSTEM YUP 250 ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover. Motor Case Mark Install a new O-ring to the front cover. Install the starter motor case, aligning the tab on the motor case with the groove on the front cover. Tighten the starter motor case screws. O-ring INSTALLATION Connect the starter motor cable.
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18. STARTING SYSTEM YUP 250 Starter Relay Wire STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire. Starter Relay OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable.