Section 05
ELECTRICAL
Subsection 04
(STARTING SYSTEM)
VMR2004_020_05_04A.FM
05-04-5
Inspect connections and clean as necessary. Sole-
noid condition can be checked with an ohmmeter.
Install test probes on large connectors of solenoid.
Measure resistance when current is applied to small
connectors; if it is more than a few ohms, replace
solenoid.
If solenoid test good, check the electric starter. If
starter test good, the electronic module can be
suspected. See ELECTRONIC MODULE below.
Electrical Cables or Connections
Check all connections, cables and wires. Tighten
any loose cables. Replace any chafe wires/cables.
If wiring and connectors are good, check the elec-
tric starter. See below.
Electric Starter
Using boosting cables, carefully supply current
from the battery directly to the starter. Connect
the BLACK (-) cable first. Then connect the remain-
ing jump cable from the battery then to the starter.
If starter now turns ensure the cables/connections
from battery to solenoid and to starter are in good
condition. If they test good, the electronic module
can be suspected. See ELECTRONIC MODULE
below.
If starter does not turn, check for mechanical prob-
lems in the starter.
Electronic Module
When other components have been tested above
and are good, the electronic module can be sus-
pected. Ensure wiring and connectors are in good
condition prior to replacing the electronic module.
ELECTRIC STARTER
REMOVAL
Turn OFF ignition switch.
Disconnect BLACK (-) cable from battery.
Disconnect RED (+) cable from starter.
Clean starter area.
Remove starter mount screws.
Pull starter out.
INSTALLATION
Installation is essentially the reverse of removal
procedure. However, pay particular attention to
the following.
Make sure that starter and engine mating surfaces
are free of debris. Serious trouble may arise if
starter is not properly aligned.
Torque starter screws to 10 N•m (89 lbf•
in
).
Connect the RED (+) cable to the starter and
torque nut to 6 N•m (53 lbf•
in
). Apply dielectric
grease on terminal and nut.
First connect RED (+) cable to battery then con-
nect the BLACK (-) cable.
Test starter operation.
CABLE TERMINAL INSTALLATION
Carefully strip the wire approximately to 12 mm
(1/2 in) in length, using a wire stripping tool or
sharp blade/knife.
A. 12 mm (1/2 in)
NOTE:
Make sure not to cut wire strands while
stripping the wire.
WARNING
Always disconnect BLACK (-) cable first and
reconnect last.
WARNING
Always connect RED (+) cable first then
BLACK (-) cable last. Whenever connecting
the RED (+) cable to the starter motor make
sure the battery cables are disconnected to
prevent electric shock.
A32E2QA
A
Summary of Contents for DS 650
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Page 2: ...Shop Manual 2004 DS 650TM DS 650TM BAJA DS 650TM BAJA X ...
