Electric Starting System

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

Below circuit diagram shows starter circuit in wiring diagram.

.

3 Main switch

   4 Fuse "IGNITION" (10A)

   5 Engine stop switch

  
26 Neutral switch

   36 Starter switch

   37 Clutch switch

38 Starting circuit cut-off relay (Relay assembly)

   39 Starter motor

40 Starter relay

   41 Battery

   42 Fuse "MAIN" (30A)  
43 Sidestand switch   45 Diode

COLOR CODE

0	Orange	Lg	Light green	B/Y	Black/Yellow
R	Red	Y/G	Yellow/Green	L/W	Blue/White
L	Blue	Y/R	Yellow/Red	L/G	Blue/Green
Br	Brown	Y/B	Yellow/Black	L/R	Blue/Red
B	Black	Y/L	Yellow/Blue	L/B	Blue/Black
Y	Yellow	Br/W	Brown/White	G/L	Green/Blue
W	White	R/B	Red/Black	G/R	Green/Red
G	Green	R/L	Red/Blue	G/Y	Green/Yellow
P	Pink	R/W	Red/White	G/W	Green/White
Dg	Dark green	R/Y	Red/Yellow	W/R	White/Red
Ch	Chocolate	B/R	Black/Red	W/B	White/Black
Gy	Gray	B/W	Black/White	W/G	White/Green
Sb	Sky blue

ELECTRIC STARTING SYSTEM

STARTING CIRCUIT OPERATION

The starting circuit on this model consists of the starter motor, starter relay, starter safety unit, and sidestand relay. If the engine stop switch and the main switch are both on, the starter motor can operate only if:

•  The transmission is in neutral (the neutral switch is on.)

•  The sidestand is up (the sidestand switch is on) and the clutch lever is pulled in (clutch switch is on).

Battery Starter motor Starter relay Starter safety unit (Relay assembly) Starter switch Neutral switch

Sidestand switch Clutch switch Sidestand relay Tachometer Main switch Engine stop switch To ignitor switch

1 Battery    2 Starter motor   3 Starter relay   4 Starting circuit cut-off relay 
5 Starter switch   6 Neutral switch   7 Sidestand switch   8 Clutch switch
9 Sidestand relay   10 Tachometer   11 Main switch  12 Engine stop switch 
13 To ignitor unit

Turn main switch to "ON" and engine stop switch to "RUN"
Transmission is
▼	▼
In neutral	In gear
▼	▼
Push starter switch Engine will start	Raise Sidestand and Pull in clutch lever
▼	▼
Ensure Sidestand is up	Push starter switch: Engine will start
▼	▼
Motorcycle can be ridden

 

TROUBLESHOOTING CHART

THE STARTER MOTOR DOES NOT OPERATE.
▼
Connect "L/W" lead from the starter relay 1 to the battery negative (-) terminal 2 ; use a jumper lead.	►	The engine does not rev smoothly.
		▼
		Recharge or replace the battery.
	►	The engine does not operate.
		▼
▼
		Check the battery voltage (12V) on the "L/W" lead from the starter relay.
The engine operates.
▼
		▼
Main and engine stop switches are turned to "ON".
		If the starter relay does not click, check the starter relay and starter motor.
▼
Connect "B/Y" lead to "ground" on the frame; use a jumper lead 1.
	►
		If the relay unit does not click, check the battery voltage (12V) on the "R/W" lead.
		▼
		Check for an open or poor connection between the main switch and relay unit.
▼
If the relay unit clicks, check the starter, sidestand, clutch and neutral switches. Replace switch(es) if necessary.

 

STARTER SAFETY UNIT (Relay Assembly)

1.     Remove:

•  Seat

•  Fuel tank

•  Relay assembly ®

2.     Check:

• Relay contacts Use 12V battery (§) and Pocket Tester (YU-03112). Out of specification — Replace relay.

Battery Connected: OH ® Battery disconnected: °° ©

DIODE

1.     Remove:

•  Left side cover

•   Diode ®

2.     Check:

•  Diode continuity/discontinuity

Defective element(s) — Replace the unit.

Checking element	Pocket tester connecting point		Good
	(+) (red)	(-) (black)
D,	G	L/W	O
	L/W	G	X
D2	Y	Sb	o
	Sb	Y	X
D3	W/G	W	o
	W	W/G	X
R	G	B/R	8.20

O: Continuity (OH) (Scale H x 1000) X : Discontinuity («>) (Scale ohm x 1)

NOTE:
The results "O" or "X" should be reversed according to the pocket tester polarity.

 

NEUTRAL SWITCH

1.  Remove:
• Left side cover
• Panel

2.  Check the neutral switch contact. Replace if out of specification.

Shift pedal 3	In neutral	In gear
Tester	0Ω	∞Ω

1 Blue lead 
2 Ground

SIDESTAND SWITCH

1. Refer to neutral switch removal steps.

2. Check the sidestand switch 1 contact. Replace switch if out of specification.

Sidestand	Up 2	Down 3
Tester	0Ω	∞Ω

CLUTCH SWITCH

1. Remove headlight unit

2. Check clutch switch contact. replace if out of specification. 

Clutch lever	Pull in	Not pull in
Tester	0Ω	∞Ω

STARTER SWITCH 

1. Remove the headlight unit.

2. Check starter switch contact. Replace if out of specification.

 

Starter switch	ON	OFF
Tester	0Ω	∞Ω

STARTER RELAY Inspection

Preparation steps:
• Disconnect starter motor red lead.
• Connect Pocket Tester leads to relay terminals.
•Turn main switch to "ON".
• Turn engine stop switch to "RUN".
• Move shift pedal to "NEUTRAL"

Push starter switch to "ON"
▼	▼
Relay clicks and tester reads 0Ω	Relay does not click and tester does not read 0 Ω
▼	▼
OK	Measure resistance:  Blue/White wire 1 to  Battery side relay terminal 2
	▼	▼
	Resistance less than 1 Ω	Resistance more than 1 Ω
	▼	▼
	Check connections	Replace relay