Checking The Starter Motor; Assembling The Starter Motor - Yamaha 2009 XP500Y TMAX Service Manual

EAS24790

CHECKING THE STARTER MOTOR

1. Check:
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut "a"
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)
0.70 mm (0.03 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
3. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification → Replace the starter
motor.
M MMM M MMM M M MMM M M MMM M
a. Measure the armature assembly resistances
with the pocket tester.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator coil resistance "1"
0.0100–0.0200 Ω at 20 °C (68 °F)
Insulation resistance "2"
Above 1 MΩ at 20°C (68°F)
b. If any resistance is out of specification, re-
place the starter motor.
M MMM M M MMM M MMM
5-33
ELECTRIC STARTER
2
L LLL L LLL L L LLL L L LLL L
4. Measure:
• Brush length "a"
Out of specification → Replace the brushes
as a set.
Limit
6.50 mm (0.26 in)
5. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force
6.02–6.51 N (21.69–23.45 oz)
(614–664 gf)
6. Check:
• Gear teeth
Damage/wear → Replace the armature as-
sembly.
EAS24800

ASSEMBLING THE STARTER MOTOR

1. Install:
• Insulator "1"
TIP
Install the insulator so that the slot "a" is posi-
tioned as shown in the illustration.
1
L LLL L L LLL L LLL