Starter Relay Removal And Installation - Suzuki LT-A400 Service Manual

1I-5 Starting System:
Carbon Brush
Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If either carbon brush is defective, replace the brush
holder set with a new one.
Measure the length "a" of the carbon brushes using a
vernier calipers. If the measurement is less than the
service limit, replace the housing end assembly with a
new one.
Brush length "a"
Service limit: 6.5 mm (0.26 in)
Special tool
: 09900–20102 (Vernier calipers (1/20 mm, 200
mm))
Commutator
Inspect the commutator for discoloration, abnormal wear
or undercut "A".
If the commutator is abnormally worn, replace the
armature.
If the commutator surface is discolored, polish it with
#400 sandpaper and wipe it using a clean, dry cloth.
If there is no undercut, scrape out the insulator (1) with a
saw blade.
Armature Coil
Measure for continuity between each segment. Measure
for continuity between each segment and the armature
shaft.
If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
armature with a new one.
Special tool
(A): 09900–25008 (Multi-circuit tester set)
Tester knob indication
Continuity set ( )
"a"
I831G1190065-01
"A"
1
I649G1190016-02
Oil Seal
Check the seal lip for damage. If any damage is found,
replace the housing end (Inside).

Starter Relay Removal and Installation

Refer to "Electrical Components Location in Section 0A
(Page 0A-6)".
Removal
1) Turn the ignition switch OFF position.
2) Remove the seat. Refer to "Exterior Parts Removal
and Installation in Section 9D (Page 9D-3)".
3) Disconnect the battery (–) lead wire from the battery.
4) Pull out the starter relay (1) from the rear fender.
5) Disconnect the starter relay coupler (2) and remove
the starter relay cover (3).
3
(A)
I649G1190017-03
I827H1190009-01
B827H11906005
2
1
I827H1190010-01