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Starter Relay
VOLTAGE
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the battery supply ter-
minal (1); then connect the black lead to the starter
terminal (2).
KM458A
3. Turn the ignition switch to the ON position. The
meter must read battery voltage.
NOTE: If battery voltage is not shown on the meter,
troubleshoot the battery connections, ground con-
nections, and starter cable connections.
4. With the transmission in neutral, depress the starter
button. There should be an audible “click” from the
starter relay and the meter should show 0 DC volts.
If the meter indicates as specified, replace the starter.
If there is no audible click and meter reads battery
voltage, proceed to step 5.
5. Disconnect the two-wire connector on the starter
relay pigtail from the main harness; then on the har-
ness side, connect the red tester lead to the yellow/
red wire and the black tester lead to the yellow/green
wire.
6. With the transmission in neutral, depress the starter
button. The meter must read battery voltage. If bat-
tery voltage is indicated, replace the starter solenoid.
If no voltage is indicated, troubleshoot the gear posi-
tion switch, starter button, ignition switch, or harness
connectors.
CDI Unit
The CDI is located beneath the seat near the battery.
NOTE: The CDI unit is not a serviceable component.
If the unit is defective, it must be replaced.
The CDI is rarely the cause for electrical problems; how-
ever, if the CDI is suspected, substitute another CDI unit
to verify the suspected one is defective.
NOTE: Prior to replacing the CDI unit to assure the
CDI unit is defective, it is advisable to perform a CDI
peak voltage test (see Ignition Coil in this section)
and/or perform a continuity test of the wiring harness
from the CDI connector to the CDI unit.
Regulator/Rectifier
The regulator/rectifier is located on the right side of the
frame. Verify all other charging system components
before the regulator/rectifier is replaced.
TESTING
1. Start the engine and warm up to normal operating
temperature; then connect a multimeter to the battery
as follows.
2. Select the DC Voltage position; then connect the red
tester lead to the positive battery post and the black
tester lead to the negative battery post.
3. Start the engine and slowly increase RPM. The volt-
age should increase with the engine RPM to a maxi-
mum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the reg-
ulator is faulty or a battery connection is loose or cor-
roded. Clean and tighten battery connections or
replace the regulator/rectifier. If voltage does not rise,
check Voltage (Stator Coil - No Load) sub-section. If
charging coil voltage is normal, replace the regulator/
rectifier.
Start-in-Gear Relay
NOTE: The relay schematic is embossed on the
relay housing for testing continuity.
NOTE: The module and wiring harness are not a
serviceable component and must be replaced as an
assembly.
TESTING
The start-in-gear relay is located under the seat below the
fuse block. To test the relay, use the following procedure.
1. Turn the ignition switch to the ON position; then
compress the brake lever or depress the auxiliary
brake pedal. There should be an audible “click” from
the start-in-gear relay.
NOTE: The brakelight should illuminate whenever
either brake is applied. If the brakelight does not illu-
minate, troubleshoot the respective brakelight
switch.
2. Apply the opposite brake from step 1. There should
be an audible “click” from the start-in-gear relay.
3. Disconnect the four-wire connector from the start-in-
gear relay; then using a voltmeter, connect the red
tester lead to the green/yellow wire (1) and the black
tester lead to the green wire (3).
Manual
Table of Contents
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