Text preview for : AGILITY50 cap 16 (imp avviamento).pdf part of Kymco Agility 50 Kymco Agility service manual



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16. STARTING SYSTEM AGILITY 50

16 Stop Switches




Starter Relay



Starter Button




Starter Motor

Starter Relay




Ignition Switch
Fuse G/Y
R/W R Y/R



G Stoplight
G/Y
Battery
G
Front Rear
Starter Motor

Stop Switches 16
16-0
16. STARTING SYSTEM AGILITY 50

SERVICE INFORMATION.......................16-1 STARTER MOTOR ................................ 16-2
TROUBLESHOOTING..............................16-1 STARTER RELAY.................................. 16-4


SERVICE INFORMATION
GENERAL INSTRUCTIONS
The removal of starter motor can be accomplished with the engine installed.


SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Starter motor brush length 12.5 8.5


TROUBLESHOOTING
Starter motor won`t turn Lack of power
Fuse burned out Weak battery
Weak battery Loose wire or connection
Faulty ignition switch Foreign matter stuck in starter motor
Faulty starter clutch or gear
Faulty front or rear stop switch
Faulty starter relay Starter motor rotates but engine does
Poorly connected, broken or shorted wire not start
Faulty starter motor Faulty starter clutch
Starter motor rotates reversely
Weak battery




16-1
16. STARTING SYSTEM AGILITY 50
Bolts
STARTER MOTOR
REMOVAL
Before removing the starter motor, turn
the ignition switch OFF and remove the
battery ground. Then, turn on the
ignition switch and push the starter
button to see if the starter motor operates
properly.

Rfmove the mrt-in box.
Remove the starter motor cable.
Remove the two starter motor mounting bolts Starter Motor Cable
and the motor. Front Cover


Remove the waterproof rubber jacket and
disconnect the starter motor cable connector.


DISASSEMBLY
Remove the two starter motor case screws,
front cover, motor case and other parts.


Motor Case Case Screws
Commutator
INSPECTION
Inspect the removed parts for wear, damage
or discoloration and replace if necessary.
Clean the commutator if there is metal
powder between the segments.




Check for continuity between pairs of the
commutator segments and there should be
continuity.
Also, make a continuity check between
individual commutator segments and the
armature shaft. There should be no
continuity.




16-2
16. STARTING SYSTEM AGILITY 50

STARTER MOTOR CASE CONTINUITY
CHECK
Check to confirm that there is no continuity
between the starter motor wire terminal and
the motor front cover.
Also check for the continuity between the
wire terminal and each brush and there
should be continuity.
Replace if necessary.



Wire Terminal

Measure the length of the brushes.
Service Limit: 8.5mm replace if below




Check for continuity between the brushes. If
there is continuity, replace with new ones.




Bearing
Check if the needle bearing in the front cover
turns freely and has no excessive play.
Replace if necessary.
Check the dust seal for wear or damage.




Dust Seal
16-3
16. STARTING SYSTEM AGILITY 50
Front Cover Commutator
ASSEMBLY
Apply grease to the dust seal in the front
cover.
Install the brushes onto the brush holders.
Apply a thin coat of grease to the two ends of
the armature shaft.
Insert the commutator into the front cover.

Be careful not to damage the brush and
armature shaft mating surfaces.
When installing the commutator, the
armature shaft should not damage the
dust seal lip.
Grease
O-ring
Install a new O-ring to the front cover.
Install the starter motor case, aligning the tab
on the motor case with the tab on the front
cover.
Tighten the starter motor case screws.

When assembling the front cover and
motor case, slightly press down the
armature shaft to assemble them.



Motor Case
Starter Relay
STARTER RELAY
INSPECTION
Remove the met-in box.
Remove the battery cover.
Remove the frame body cover. ( 2-2)
Turn the ignition switch ON and the starter
relay is normal if you hear a click when the
starter button is depressed.
If there is no click sound:
Inspect the starter relay voltage
Inspect the starter relay ground circuit
Inspect the starter relay operation

STARTER RELAY VOLTAGE INSPECTION
Place the motorcycle on its main stand.
Measure the voltage between the starter relay
connector green/yellow wire (-) and engine
ground.
Turn the ignition switch ON and the battery
voltage should be normal when the brake
lever is fully applied.
If the battery has no voltage, inspect the stop
switch continuity and cable.
Turn to the DCV position for the voltage
meter, then inspect the starter relay. Green/Yellow Wire
16-4
16. STARTING SYSTEM AGILITY 50
Starter Relay
STARTER RELAY TEST
Remove the battery cover.
Disconnect the 4P connector from the starter
relay and remove the starter relay.




Connect the starter relay (D) terminal to the
12V battery positive (+) terminal and the
relay (C) terminal to the battery negative (-)
terminal. Check for continuity between the
starter relay (A) and (B) terminals. The
relay is normal if there is continuity.




Bolts
STARTER MOTOR INSTALLATION
Apply engine oil to the starter motor O-ring
and install the starter motor.
Tighten the two mounting bolts.
Connect the starter motor cable connector.




Connector Starter Motor




16-5