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Magneto Coils
VOLTAGE (Charging Coil - Output)
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the positive battery
post; then connect the black tester lead to the nega-
tive battery post.
3. With the engine running at a constant 5000 RPM
(with the headlights on), the meter must show 14-
15.5 DC volts.
NOTE: If voltage is lower than specified, test charg-
ing coil - no load.
VOLTAGE (Charging Coil - No
Load)
The connector is the black and white one on the right rear
side of the frame just above the regulator/rectifier.
NOTE: Test the connector that comes from the
engine.
1. Set the meter selector to the AC Voltage position.
2. Test between the three yellow wires for a total of
three tests.
3. With the engine running at the specified RPM, all
wire tests must show as specified.
NOTE: If both voltage tests failed, check all connec-
tions, etc., and test again. If no voltage is present,
replace the stator assembly.
RESISTANCE (Charging Coil)
1. Set the meter selector to OHMS position.
2. Test between the three yellow wires for a total of
three tests.
3. The meter reading must be within specification.
RESISTANCE (Trigger Coil)
The trigger coil connector is located under the seat at the
rear of the air filter housing.
1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the blue wire; then con-
nect the black tester lead to the green wire. The
meter reading must be within specification.
RESISTANCE (Signal Coil)
The signal coil connector is located under the seat at the
rear of the air filter housing.
1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the black wire; then
connect the black tester lead to ground. The meter
reading must be within specifications.
PEAK VOLTAGE
NOTE: All of the peak voltage tests should be made
using the Fluke Model 77 Multimeter with Peak Volt-
age Reading Adapter. If any other type of tester is
used, readings may vary due to internal circuitry.
NOTE: The battery must be at full charge for these tests.
Trigger Coil
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the blue wire; then con-
nect the black tester lead to the green wire.
3. Crank the engine over using the electric starter.
4. The meter reading must be within specification.
Signal Coil
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the black wire (engine side);
then connect the black tester lead to a suitable ground.
3. Crank the engine over using the electric starter.
4. The meter reading must be within specifications.
Starter Motor
NOTE: The starter motor is not a serviceable com-
ponent. If the starter motor does not operate, see
Starter Relay. If the relay tests normal, replace the
starter motor.
REMOVING/INSTALLING
1. Disconnect the battery.
2. Remove the nut securing the positive cable to the
starter; then remove the cable from the starter.
3. Remove the two cap screws securing the starter to
the crankcase; then remove the starter. Account for
the wiring forms and an O-ring.
4. Install the new starter motor; then tighten the cap
screws to 7 ft-lb.
CAUTION
Do not run the engine at high RPM for more than 10 sec-
onds.
CAUTION
Do not run the engine at high RPM for more than 10 sec-
onds.
CAUTION
Always disconnect the battery when performing resis-
tance tests to avoid damaging the multimeter.
CAUTION
Always disconnect the battery when performing resis-
tance tests to avoid damaging the multimeter.
CAUTION
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.
