Yamaha YZF-R15, Service Manual

Page: 196 / 338

5-33
ELECTRIC STARTER
Disassembling the starter motor
Order Job/Parts to remove Qty Remarks
1 O-ring 1
2 Starter motor yoke 1
3 O-ring 1
4 Commutator 1
5 Starter motor front cover/brush holder set 1
6 Brush 2
7 Brush spring 2
For assembly, reverse the disassembly pro-
cedure.
New
New
5-34
ELECTRIC STARTER
DISASSEMBLING THE STARTER MOTOR
1. Remove:
• Starter motor yoke “1”
• Starter motor front cover/brush holder set “2”
NOTE:
Before disassembling the starter motor, make
alignment marks “a” on the starter motor yoke
and starter motor front cover/brush holder set.
CHECKING THE STARTER MOTOR
1. Check:
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter
motor.
3. 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.
NOTE:
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
4. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification
→ Replace the starter
motor.
a. Measure the armature assembly resistances
with the multimeter.
b. If any resistance is out of specification, re-
place the starter motor.
5. Measure:
• Brush length “a”
Out of specification → Replace the starter
motor front cover/brush holder set.
Limit
16.6 mm
Mica undercut (depth)
1.35 mm
a
1
2
a
Multimeter
Limit
3.50 mm
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Armature coil
Commutator resistance “1”
0.0315–0.0385 Ω at 20 °C (68 °F)
Insulation resistance “2”
Above 1 M Ω at 20 °C (68 °F)